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20th CIRP Conference on Electro Physical and Chemical Machining, ISEM 2020

作者： Uhlmann, Eckart Polte, Julian Bolz, Robert Yabroudi, Sami Streckenbach, Jan Bergmann, André Fraunhofer Institute for Production Systems and Design Technology Pascalstrasse 8-9 Berlin10587 Germany Technische Universität Berlin Chair of Machine Tools and Manufacturing Technology Pascalstrasse 8-9 Berlin10587 Germany

Application fields of electrical discharge machining (EDM) are limited due to given process conditions. Manufacturing of parts with high aspect ratios and the application of multi-axis machining are limited due to process instabilities caused by removed particles. A promising approach to improve EDM process conditions, especially in sinking EDM (S-EDM), is the utilization of flushing channels in the tool electrode. However, with increasing complexity of the tool electrode geometry and the local integration of these flushing channels, conventional tool electrode manufacturing by cutting is limited. In contrast to that, the machining process selective laser melting (SLM) does not have such limitations. The appropriate integration of flushing channels, even for complex electrode geometries, improves process conditions during EDM in a variety of applications. This leads to a higher material removal rate and reduced tool wear compared to machining without flushing. Additionally, the number of required tool electrodes can be reduced, as SLM enables an efficient integration and miniaturization of all features in a single electrode. Because of its wear resistance and stability, tungsten carbide is an ideal tool electrode material, which is commonly applied in drilling EDM. After identifying suitable process parameters for roughing EDM with additively manufactured tungsten carbide cobalt tool electrodes, different forms of flushing channels were analysed in order to establish a fast process with minimum tool electrode wear. The results concerning material removal rate and the relative tool wear could be improved by applying internal flushing, though the tool wear stayed at a worse level compared to conventional tool electrode materials. © 2020 The Authors. Published by Elsevier B.V.

关键词： Tungsten carbide

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Harmonization of Heterogeneous Asset Administration Shells

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Procedia CIRP 2022年 107卷 95-100页

作者： Nikolaos-Stefanos Koutrakis Varun Gowtham Wenzel Baron Pilar von Pilchau Thomas Josef Jung Julian Polte Jörg Hähner Marius-Iulian Corici Thomas Magedanz Eckart Uhlmann Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer FOKUS Kaiserin-Augusta-Allee 31 10589 Berlin Germany University of Augsburg Am Technologiezentrum 8 86159 Augsburg Germany Robert Bosch GmbH Robert-Bosch-Campus 1 71272 Renningen Germany Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Pascalstr. 8-9 10587 Berlin Germany

In the era of digital transformation of the manufacturing and process industry, heterogeneity of assets is one of the most challenging issues towards digitally integrating components within the Industrial Internet of Things. In this context every participant relies on its proprietary digitalization approach envisioned by Plattform Industrie 4.0. To consolidate these heterogeneous data exchange interfaces, e.g. communication protocols, data formats etc., an intermediate step of harmonization is required. Our contribution provides an architecture based on the Asset Administration Shell standard to bring heterogeneous Cyber-Physical-Systems together. We illustrate the functionality through an abstract use-case.

关键词： Asset Administration Shell Digital Twin Virtual Sensor Sensor Networks IIoT I4.0 MQTT OPC UA

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Simulation of metal cutting with cutting fluid using the Finite-Pointset-Method

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Procedia CIRP 2021年 101卷 98-101页

作者： Eckart Uhlmann Enrico Barth Tobias Seifarth Maximilian Höchel Jörg Kuhnert Almut Eisenträger Institute for Machine Tools and Factory Management (IWF) Technische Universität Berlin Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Industrial Mathematics ITWM Fraunhofer-Platz 1 67663 Kaiserslautern Germany

Despite the common use of cutting fluids in metal cutting, most simulations of these processes only consider dry conditions. This is largely due to limitations in conventional simulation methods, such as the Finite Element Method (FEM), regarding fast changing computational domains. In this paper, a simulation model of metal cutting with cutting fluid based on the Finite Pointset Method (FPM) is presented. This approach allows to simulate the Fluid-Structure-Interactions (FSI) within the same simulation method. For different orthogonal turning processes, the simulations are compared with experiments for dry and wet conditions. The simulation results illustrate the cooling effect numerically.

关键词： Simulation Fluid Turning

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Linked Data Architecture for Assistance and Traceability in Smart Manufacturing

Linked Data Architecture for Assistance and Traceability in ...

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9th EASN International Conference on Innovation in Aviation and Space, EASN 2019

作者： Friedemann, Marko Wenzel, Ken Singer, Adrian 1Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Traceability systems and digital assistance solutions are becoming increasingly vital parts of modern manufacturing environments. They help tracking quality-related information throughout the production process and support workers and maintenance personnel to cope with the increasing complexity of manufacturing technologies. In order to support these use cases, the integration of information from different data sources is required to create the necessary insights into processes, equipment and production quality. Common challenges for such integration scenarios are the various data formats, encodings and software interfaces that are involved in the acquisition, transmission, management and retrieval of relevant product and process data. This paper proposes a Linked Data based system architecture for modular and decoupled assistance software. Its web-oriented approach allows to connect two usually disparate data sets: semantic descriptions of complex production systems on the one hand and high-volume and high-velocity production data on the other hand. The proposed concept is illustrated with a typical example from the manufacturing domain. The described End-of-Line quality assessment on forming machines is used for traceability and product monitoring. © The Authors, published by EDP Sciences, 2019.

关键词： Linked data

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Measurement and Modeling of Contact Forces during Robot-guided Drag Finishing

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Procedia CIRP 2021年 102卷 518-523页

作者： Eckart Uhlmann Marco Kopp Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstr. 8-9 10587 Berlin Germany

Robot-guided drag finishing is a free abrasive grinding operation that is used for polishing and deburring of workpieces with complex shaped geometries. The workpiece is attached to a robot and moved through a bulk of abrasive particles. The motion of abrasive particles during contact with the workpiece is the basis of the material removal mechanisms. To investigate the motion of abrasive particles during contact, a force measurement system was used to determine contact forces. The experimental setup was replicated in a numerical simulation based on the discrete element method (DEM). Based on the comparison of experimental and simulative results the qualitative validity of the DEM model was concluded. With the presented DEM model, the characteristic particle behavior during contact with the workpiece can be modeled which allows the prediction of resulting processing marks. Consequently, the DEM model can be used to design free abrasive grinding operations without using the time and cost intensive trial and error approach.

关键词： robot-guided drag finishing discrete element method process design validation contact forces

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Numerical investigation on the process behavior of a closed-loop internal cooling system for turning operations

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Procedia CIRP 2021年 102卷 73-78页

作者： E. Uhlmann P. Meier Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstr. 8-9 10587 Berlin Germany

The development of sustainable manufacturing processes and the associated reduction of operating materials such as cooling lubricants represent key focuses on recent production technology. Thus, a novel tool system with a closed-loop internal cooling system for turning operations is presented in this study. The system design is based on numerical investigations of the heat flow Q⋅ with consideration of the thermomechanical load of the cutting tool and flow characteristics of the cooling fluid. The process behavior of the proposed system shows a significant dependence of the flow rate V⋅ and tool thickness t T in terms of tool temperature reduction Δθ T .

关键词： Turning Cooling Sustainable manufacturing

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Approach for a production control system within metal-based additive manufacturing

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Procedia CIRP 2021年 99卷 39-44页

作者： Steffen Ziegler Sabrina Struller Philipp Scherwitz Gunther Reinhart Fraunhofer Institute for Casting Composite and Processing Technology IGCV Am Technologiezentrum 10 86159 Augsburg Germany Institute for Machine Tools and Industrial Management (iwb) Technnical University of Munich Boltzmannstr. 15 85748 Garching bei München Germany

In the face of challenges such as limited resources and climate change, aerospace companies strive for efficiency and sustainability in their manufacturing processes. By means of Additive Manufacturing (AM), new dimensions in terms of cost-effective and bionic lightweight structures are achievable. Even though AM results in the direct manufacturing of components, a variety of post-processing steps has to be implemented in the manufacturing line. By selecting a suitable automatic identification and data capture (Auto-ID) system, a production control system is capable of responding in real time to unforeseen events, while reducing waste caused, for exemple, through unnecessary processing steps. Thus, this paper focuses on an approach for a production control system for a manufacturing line including metal-based AM process.

关键词： Additive manufacturing Production planning control Aerospace industry

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Decision Approach for the Design and Sensor Integration of an LPBF Manufactured Gripper End Effector

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Procedia CIRP 2021年 104卷 128-133页

作者： Günther Schuh Georg Bergweiler Martin Zäpfel Anurag Salian Philipp Bickendorf Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany Fraunhofer Institute for Casting Composite and Processing Technology IGCV Am Technologiezentrum 10 86159 Augsburg Germany

In the context of increasing digitalisation of production, more and more data is required, while demands on the handling of production resources e.g. gripper for industrial robots are increasing. Currently, the potential of captured data is not being exploited and hardly any data is used with the help of production resources. In this paper, a decision process for the integration of a temperature sensor in Laser Powder Bed Fusion (LPBF) printed end effectors which considers all steps of the design is presented. The result is a 3D-printed adapted design of an end effector which is optimised regarding the requirement profile.

关键词： Additive Manufacturing Production technology Rapid tooling Sensor Integration Gripper End Effector Laser Powder Bed Fusion

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Potentials of Bluetooth Low Energy Beacons for order tracing in single and small batch production 8

Potentials of Bluetooth Low Energy Beacons for order tracing...

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8th CIRP Conference of Assembly technology and Systems, CATS 2020

作者： Elser, Hannes Jongebloed, Philip Buschmann, Daniel Ellerich, Max Schmitt, Robert H. Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 Aachen52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstrasse 17 Aachen52074 Germany

The quality of production planning and control in production companies largely depends on the accuracy of the database regarding the status quo of the production process, as well as the time required for each production step. Especially in single and small batch production, it is difficult to create a reliable database due to the large product spectrum and the variation in the production process. For this reason, this paper examines the potential of Bluetooth Low Energy (BLE) Beacons to create a low-cost real-time locating system (RTLS). In comparison to other existing RTLS solutions like RFID, BLE stands out through very low hardware costs and a high compatibility to almost every mobile device. Through a signal strength based approach in combination with probabilistic neural networks, the RTLS has been able to achieve a positioning accuracy with a mean absolute error of up to 0,74 m in an industry-like environment. © 2020 Elsevier B.V.. All rights reserved.

关键词： Bluetooth

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Experimental investigation of abrasive properties in waterjet machining

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Procedia CIRP 2021年 101卷 210-213页

作者： M. Schüler M. Dadgar T. Herrig A. Klink T. Bergs Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany

Abrasive waterjet (AWJ) machining has proven to be one of the most flexible non-conventional production techniques for difficult-to-machine materials. However, the prediction of process results is challenging since multiple physical processes occur simultaneously. Until now, the use of alternative abrasive material for special applications has received limited attention. In this work, different solid materials of altered shape and mechanical properties were used to analyze the physical phenomena experimentally. A ceramic and a steel abrasive material of either circular or angular geometry were used. The experiments were conducted by AWJ controlled-depth machining on 42CrMo4 steel in various structural modifications regarding the interference of particle interactions. Furthermore the study aims to gain a fundamental understanding of the AWJ erosion process of different abrasive grit for a better prediction and optimization of AWJ machining, in particular for future applications.

关键词： Waterjet machining Abrasion Abrasive Properties

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