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Influence of cutting edge radius on process forces in orthogonal machining of carbon fibre reinforced plastics (CFRP)

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Procedia CIRP 2019年 85卷 218-223页

作者： Konstantin Sauer Marco Witt Matthias Putz Institute for Machine Tools and Production Processes Chemnitz University of Technology 09111 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

Carbon fibre reinforced plastics (CFRP) are commonly used in the aerospace and automotive industries to reduce the mass of parts and assemblies with the goal of improving energy efficiency. When machining with geometrically defined cutting edge, the cutting edge radius of the tool is a quality-determining feature and should be kept as low as possible to enable precise separation of the fibres. It is raised by the use of coatings and by cutting edge wear. The aim of this paper is to evaluate the influence of the cutting edge radius on thrust force and cutting force when machining CFRP using an orthogonal cut. It is intended to map the drilling process by means of an orthogonal cut at certain fibre cutting angles. A new method of orthogonal machining has been developed for this purpose that considers the fibre preload and the feed movement of a drill. The fibre orientation was varied in the tool cutting edge plane. The application of small depths of cut in combination with different cutting edge radii enable the investigation of the effect of different cutting edge regions on the process forces. For this purpose, a new method for cutting edge preparation is proposed, based on the abrasive waterjet. Accordingly, the paper increases the understanding of the process when machining with high cutting edge radius.

关键词： Composite Cutting edge Machining Orthogonal cut CFRP Process force

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Dry sheet metal forming of aluminum by smooth DLC coatings – a capable approach for an efficient production process with reduced environmental impact

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Procedia Manufacturing 2020年 43卷 642-649页

作者： T. Abraham G. Bräuer F. Flegler P. Groche M. Demmler Fraunhofer-Institut for Surface Engineering and Thin Films Bienroder Weg 54E 38108 Braunschweig Germany Institute for Production Engineering and Forming Machines Technische Universität Darmstadt 64287 Darmstadt Germany Fraunhofer-Institut for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

Currently a high amount of lubricants is used in aluminum forming processes to ensure a long tool lifetime and a high product quality. These technological and economical goals are traded for a negative environmental impact caused by the usage of lubricants. One approach to reduce the environmental impact is the utilization of dry forming of aluminum. Therefore, alternative methods for a tribological optimization need to be implemented like the deposition of tool coatings. Diamond like carbon (DLC) coatings are well known for their exceptional tribological properties. However, state of the art DLC coatings fail due to rapid formation of aluminum adhesions. In this paper, the nanoscopic roughness of DLC coatings will be presented as a critical property for preventing the formation of aluminum adhesions and enabling dry forming of aluminum. For this purpose, an amorphous hydrogenated carbon (a-C:H) coating will be deposited, subsequently polished and characterized to validate the impact of the material selection and surface treatment on the coating roughness. For an evaluation of the tribological properties, polished and unpolished a-C:H coatings will be tested in application oriented strip drawing and industry-oriented deep drawing tests. These tests demonstrate the capability of smooth a-C:H tool coatings to enable dry forming of aluminum with a reduced environmental impact.

关键词： Tribology Coating Metal forming

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Boron-doped monocrystalline diamond as cutting tool for temperature measurement in the cutting zone

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Procedia CIRP 2021年 101卷 258-261页

作者： E. Uhlmann J. Polte M. Polte T. Hocke Institute for Machine Tools and Factory Management (IWF) Technische Universität Berlin Pascalstraße 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstraße 8-9 10587 Berlin Germany

Ultra-precision machining is a key technology for manufacturing optical surfaces in a broad range of automotive and aerospace applications. At the state of the art, no precise methods for analysing the temperatures in the cutting zone of a monocrystalline diamond tool are available. Precise cutting temperatures are required for a detailed analysis of the wear behaviour. High response times and low measurement accuracies are still challenges. In this work, a new approach for a precise temperature measurement using boron-doped diamonds is shown. The sensor properties of boron-doped diamonds were analysed and experimental investigations to show the suitability were carried out. First results show a great potential as measurement method for real time temperatures during the cutting process.

关键词： temperature sensor diamond tool measurement system ultra-precision machining

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Pressure conditions during the immersed tumbling process

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Procedia CIRP 2021年 101卷 198-201页

作者： E. Uhlmann J. Polte M. Polte Y. Kuche Institute for Machine Tools and Factory Management (IWF) Technische Universität Berlin Pascalstraße 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstraße 8-9 10587 Berlin Germany

An approach to improve the tool wear behaviour of milling tools made of cemented carbide is a defined cutting edge preparation usingthe immersed tumbling process. One significant factor that influences cutting edge preparation is the effective pressure generated by the relative movement of the cutting tools and the abrasive particles. However, the development and influence of the process pressure has been discussed almost exclusively based on machining and preparation results. For a profound process understanding a wireless force measurement system was designed and the pressure forces of two media were examined. The influences of the used lapping media, the velocityas well as the depth of immersion using a simplified linear movement were analysed. The results provide information about the pressure conditions that change in the real process.

关键词： Cutting edge Finishing Force Measurement

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Structured data preparation pipeline for machine learning-applications in production 17

Structured data preparation pipeline for machine learning-ap...

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17th IMEKO TC 10 and EUROLAB Virtual Conference: Global Trends in Testing, Diagnostics and Inspection for 2030

作者： Frye, Maik Schmitt, Robert Heinrich Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 Aachen52074 Germany Laboratory for Machine Tools WZL RWTH Aachen University Cluster Production Engineering 3A 540 Aachen52074 Germany

ISBN: (纸本)9781713820444

The application of machine learning (ML) is becoming increasingly common in production. However, many ML-projects fail due to the existence of poor data quality. To increase its quality, data needs to be prepared. Through the consideration of versatile requirements, data preparation (DPP) is a challenging task, while accounting for 80 % of ML-projects duration [1]. Nowadays, DPP is still performed manually and individually making it essential to structure the preparation in order to achieve high-quality data in a reasonable amount of time. Thus, we present a holistic concept for a structured and reusable DPP-pipeline for ML-applications in production. In a first step, requirements for DPP are determined based on project experiences and detailed research. Subsequently, individual steps and methods of DPP are identified and structured. The concept is successfully validated through two production use-cases by preparing data sets and implementing ML-algorithms. © Global Trends in Testing, Diagnostics and Inspection for *** rights reserved.

关键词： machine learning

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Comparison of 5G enabled control loops for production 31

Comparison of 5G enabled control loops for production

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31st IEEE Annual International Symposium on Personal, Indoor and Mobile Radio Communications, PIMRC 2020

作者： Kehl, Pierre Lange, Dr. Dirk Konstantin Maurer, Felix Nemeth, Gabor Overbeck, Daniel Jung, Sven Konig, Niels Schmitt, Prof. Robert H. Fraunhofer Institute for Production Technology IPT Digital Infrastructures Aachen Germany Marposs Monitoring Solutions GmbH Development ARTIS DIVISION Egestorf Germany Fraunhofer Institute for Production Technology IPT High Performance Cutting Aachen Germany Ercisson Research Budapest Hungary Fraunhofer Institute for Production Technology IPT Production Metrology Aachen Germany Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen University Aachen Germany

ISBN: (纸本)9781728144900

Concepts such as Industry 4.0 and Industrial Internet of Things aim for a digital transformation of manufacturing companies. One aspect that is to be transformed is the shop floor, where the interconnection of machines and sensor devices plays a major role. 5G positions itself to be a key technology to enable this transformation by providing reliable, low latency, and high bandwidth communication which is required by industrial use cases. However, so far it is still unclear which role 5G will play in industrial networks and how it can be integrated into existing factory ecosystems. Therefore, this paper presents three different data flow architectures that illustrate how 5G can be integrated into the production IT and how it can coexist with a factory cloud system. Furthermore, we describe a use case that reflects typical industrial communication requirements and will be used in the future to evaluate the different architectures. We conclude by presenting a validation plan and an outlook on future work. © 2020 IEEE.

关键词： Industry 4.0

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Inverse hybrid laminate for lightweight applications 5th

Inverse hybrid laminate for lightweight applications

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5th International Conference on Composite Materials and Material Engineering, ICCMME 2020

作者： Osiecki, Tomasz Gerstenberger, Colin Timmel, Tristan Frankiewicz, Mariusz Dziedzic, Robert Scholz, Peter Kroll, Lothar Institute of Lightweight Structures and Polymer Technology Technische Universität Chemnitz Reichenhainer Str. 31-33 Chemnitz09126 Germany Wroclaw University of Science and Technology ul. Lukasiewicza 5 Wroclaw50-371 Poland Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Opole University of Technology Prószkowska 76 Street Opole45-758 Poland

ISBN: (纸本)9783035716191

Because of their high specific stiffness and strength, fiber reinforced plastics (FRP) are preferred lightweight materials. Recent developments show a growing industrial interest in the integration of thermoplastic FRP in complex structures for high volumes. However, there are still shortcomings for these materials concerning the insufficient energy absorption in case of failure and the limited opportunities available for the assembly with other components. Improvements in the crash performance can be achieved for instance with the selective reinforcement of the FRP structure with ductile metallic inserts. The present study shows the interlaminar shear strength and scanning electron microscope (SEM) samples of a novel load optimized hybrid composite consisting of a continuous fiber-reinforced thermoplastic matrix, in which a metal core is integrated. © 2020 Trans Tech Publications Ltd, Switzerland.

关键词： Fiber reinforced plastics

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Structure protects function - An enabler for the functionalization of component surfaces by biohybrid coatings

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Procedia CIRP 2022年 110卷 133-138页

作者： Thomas Bergs Ulrich Schwaneberg Sebastian Apelt Felix Jakob Cesar Rodriguez-Emmenegger Alexander Beckers Abdulkadir Yayci Maximilian Nöth Manuela Garay-Sarmiento Sebastian Barth Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany DWI - Leibniz Institute for Interactive Materials e.V. Forckenbeckstraße 50 52074 Aachen Germany Chair of Biotechnology RWTH Aachen University Worringerweg 3 52074 Aachen Germany

The biological transformation is a growing part of current research in manufacturing and enables new possibilities in the development of innovative products. Modular functional assemblies based on biological building blocks potentially enable efficient and economical functionalization of component surfaces. Surface functionalization covers a range of industries and applications with high economic and technological potential and societal relevance. In dentistry, inflammation of the gums near the implant (periimplant infection) is one of the most common complications after implant implantation. The infections are mainly due to bacterial contamination or bacterial colonization at the implant. Biohybrid coatings based on modular functional assemblies represent an innovative solution for surface functionalization to prevent these periimplant infections. However, in addition to the advantages of modular functional assemblies, there are various challenges for the establishment of functional assemblies in series production. These pose new requirements for the manufacturing technology. The aim of interdisciplinary collaboration between biotechnology, soft matter nanotechnology, polymer chemistry, and production engineering is to provide implant surfaces (using titanium dental implants as an example) with an innovative biohybrid coating in combination with microstructuring. The coating prevents the bacterial colonization of the implant while the microstructure increases the robustness and longevity of the coating. The challenges in manufacturing these micro-structures of surfaces, the generation of biohybrid coatings as well as an outlook on the innovative use of functionalized surfaces are described in this paper.

关键词： Biologicial building blocks modular functional assemblies surface functionalization surface modification

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Manufacturing of glass fibre/PBT-spincom yarns for innovative composite processing 18

Manufacturing of glass fibre/PBT-spincom yarns for innovativ...

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18th European Conference on Composite Materials, ECCM 2018

作者： Scheffler, Christina Hiller, Janett Krüger, Matthias Haase, Rico Weise, Dieter Garray, Didier Spickenheuer, Axel Leibniz-Institut für Polymerforschung Dresden e.V. Dept. Composite Materials Hohe Straße 6 Dresden01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dept. Business Unit Car Bodies and Cell Structures Chemnitz Germany SIRRIS Seraing Liège/Wallonia Belgium

ISBN: (纸本)9781510896932

The aim of this work was the development of GF (glass fibre)/ PBT (polybutylene therephthalate) SpinCOM yarns that are commingled online during the spinning process using sizing formulations that enable textile processability as well as high fibre-matrix interaction. Epoxy- and polyurethane-based sizings have been applied and were evaluated by micromechanical (single fibre pull-out test) and macromechanical (transverse tensile test of unidirectional plates) testing. Finally, a material combination was selected to be processed by Tailored Fiber Placement (TFP) to textile preforms with a variable-axial, load adapted fiber design. These preforms were consolidated in a low energy and resource consuming process using novel light and low cost forming tools produced by incremental sheet metal forming (ISF) technology. Finally, a low cost solution for thermal processing even for complex shaped TPC parts is demonstrated by the geometry of a bicycle saddle. © CCM 2020 - 18th European Conference on Composite Materials. All rights reserved.

关键词： Polybutenes

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Additive manufacturing technologies for next-generation powertrains

Additive manufacturing technologies for next-generation powe...

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International Electric Drives Production Conference (EDPC)

作者： Philipp Fiedler Sebastian Stelzer Nikolaus Milaev Robert Richter Frank Kaulfuß Thomas Windisch Jan Bräunig Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany 3D-Printpetrol Großenhain Germany Fraunhofer Institute for Material and Beam Technology IWS Dresden Germany Division Engineering of Adaptive Systems Fraunhofer IIS/EAS Fraunhofer Institute for Integrated Circuits Dresden Germany

ISBN: (数字)9781728184586

ISBN: (纸本)9781728196145

The paper addresses the prototypical development and implementation of an innovative and functionally integrated gear stage for next-generation electric vehicles, produced by using Laser Beam Melting (LBM) and Fused Deposition Modeling (FDM). Two new design targets are addressed by our approach: Oil-free operation is achieved by innovative coating of gear teeth which enables almost maintenance-free operation. Furthermore, a higher damping of sound transmission from tooth mesh to bearings is implemented by an optimal wheel body geometry that is realized by a combination of printable carbon-containing polymers (flange) and steel (gear rim). The innovative approach is to extend components by areas that cannot be produced by milling and casting, e.g. complex structures, contour-following fluid-carrying cooling elements by means of LBM, thus creating a significant benefit compared to state-of-the-art gearboxes. Function integration made possible by additive manufacturing results in a very high component complexity. It is combined with gear grinding and final ta-C coatings ensuring maximum efficiency in dry operation, to achieve economically viable production processes. The increase in tooth mesh efficiency is achieved by optimization approaches in the design to minimize heat losses while at the same time maintaining highest possible strength and lowest noise emission.

关键词： Gears Wheels Production Three-dimensional printing Laser beams Coatings Next generation networking

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