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20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020

作者： Uhlmann, E. Polte, J. Koprowski, S. Kochan, J. Borsoi Klein, T. Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany

ISBN: (纸本)9780995775176

The constant development and improvement of mechanical and chemical properties of high performance ceramics allows the expansion of its actual applications. In comparison to metal materials, the use of novel high performance components can offer numerous advantages. In turbomachinery, a full ceramic impeller can fulfil the requirements of efficiency and high turbine inlet temperatures combined with lower cooling requirements, reduced combustion emissions and fuel consumption. This is feasible not only thanks to the properties of the ceramics, but also by the interaction of this with simulation, design optimization, manufacturing processes and a high quality finishing by hard machining. However, the machining of brittle material components with complex geometries remains a challenge in terms of resultant surface characteristics, tribological properties, geometric accuracy and process costs. In this scenario, 5-axis grinding with mounted points and innovative strategies provide new possibilities for the manufacturing of these complexes components. The current work aims at a practice-oriented design and the following hard machining of a hot isostatically pressed silicon nitride (HIPSN) impeller with complex geometry and high requirements, gathering low geometrical deviations, reduced brittle fractures and roughness at the ground part. To achieve these objectives, different machining strategies and parameters are tested and correlated with the resulting quality of the component. Simulation techniques are also shown to ensure optimum operating conditions for the ceramic component. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Silicon nitride

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Dry-ED milling of micro-scale contours with high-speed rotating tungsten tube electrodes

Dry-ED milling of micro-scale contours with high-speed rotat...

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

作者： Uhlmann, E. Perfilov, I. Yabroudi, S. Mevert, R. Polte, M. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

This paper presents machining results for dry-ED milling of micro-scale contours by use of a new machine tool, including a relaxation generator, designed for dry-EDM. To implement the dry-ED milling process tungsten tube electrodes were used. The gas is injected through the tubular tool electrode under high pressure. Additionally, a high-speed EDM spindle was used to overcome process instabilities and increase the material removal rate due to better flushing conditions. Further, fluid simulations of the flushing conditions are presented in this paper. It is found that the use of gaseous dielectrics enables much better machining results in terms of shape accuracy and tool wear. The simulations provide new insights in the flushing conditions when using gaseous dielectrics. The calculated fluid flow pattern shows a great agreement with the observed depositions of reattached molten material on the tool and workpiece surface. The results presented as well as the hardware introduced enable the industrial application of dry-EDM for the first time. © 2020 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://***/licenses/by-nc-nd/4.0/) Peer-review under responsibility of the scientific committee of the ISEM 2020

关键词： Computational fluid dynamics

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Towards predictive quality in production by applying a flexible process-independent meta-model 54

Towards predictive quality in production by applying a flexi...

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54th CIRP Conference on Manufacturing Ssystems, CMS 2021

作者： Liang, Junjie Pelzer, Lukas Müller, Kai Cramer, Simon Greb, Christoph Hopmann, Christian Schmitt, Robert H. RWTH Aachen University Laboratory for Machine Tools and Production Engineering Campus-Boulevard 30 Aachen52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 Aachen52074 Germany RWTH Aachen University Institute for Plastics Processing Seffenter Weg 201 Aachen52074 Germany RWTH Aachen University Institut für Textiltechnik Otto-Blumenthal-Straße 1 Aachen52074 Germany

Predictive Analytics is increasingly applied as a basis for decision-making in product and process optimization of manufacturing companies. In this context, Predictive Quality enables companies to make data-driven predictions of product quality, with data integration being one of the most significant challenges. This paper provides insights into exemplary applications of a flexible process-independent meta-model to integrate data for multi-step manufacturing processes. Three application use cases from different production domains are presented, demonstrating the meta-model's applicability for Predictive Quality applications in manufacturing companies without restrictions regarding the product or manufacturing process. © 2021 The Author(s).

关键词： Predictive analytics

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Potentials of Hydrogen Technologies for Sustainable Factory Systems 28

Potentials of Hydrogen Technologies for Sustainable Factory ...

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28th CIRP Conference on Life Cycle Engineering, LCE 2021

作者： Imdahl, Christoph Blume, Christine Blume, Stefan Zellmer, Sabrina Gensicke, Michael Herrmann, Christoph Fraunhofer Institute for Surface Engineering and Thin Films Ist Bienroder Weg 54E Braunschweig38108 Germany Institute of Machine Tools and Production Technology Chair of Sustainable Manufacturing and Life Cycle Engineering Technische Universität Braunschweig Langer Kamp 19b Braunschweig38106 Germany Robert Bosch Elektronik GmbH John-F.-Kennedy-Straße 43-53 Salzgitter38228 Germany

The industrial sector is the world's second largest emitter of greenhouse gases, hence a methodology for decarbonizing factory systems is crucial for achieving global climate goals. Hydrogen is an important medium for the transition towards carbon neutral factories due to its broad applicability within the factory, including its use in electricity and heat generation and as a process gas or fuel. One of the main challenges is the identification of economically and environmentally suitable design scenarios, such as for the entire value chain for hydrogen generation and application. For example, the infrastructure for renewable electricity, hydrogen generation, hydrogen conversion (e.g. into synthetic fuels), storage and transport systems as well as application in the factory. Due to the high volatility of energy generation and the related dynamic interdependencies within a factory system, a valid technical, economic and environmental evaluation of benefits induced by hydrogen technologies can only be achieved using digital factory models. In this paper, we present a framework to integrate hydrogen technologies into factory systems. This enables decision makers to identify promising measures according to their expected impact and collect data for appropriate factory modelling. Furthermore, a concept for factory modelling and simulation is presented and demonstrated in a case study from the electronics industry, assessing the use of hydrogen for decentralized power and heat generation. © 2021 Elsevier B.V.. All rights reserved.

关键词： Digital storage

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A Survey on Automatic Model Generation for Material Flow Simulation in Discrete Manufacturing

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Procedia CIRP 2019年 81卷 121-126页

作者： Heiner Reinhardt Marek Weber Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany

Adaptivity of production systems is acknowledged as a key competition factor in the manufacturing industry. In order to decrease reaction time and increase cost efficiency, changes to a production system are often planned and validated using material flow simulation. However, repeated manual synchronization of the simulation model with the real manufacturing environment is time-consuming and error-prone. Automatic simulation model generation (ASMG) could overcome these issues. In contrast to recent surveys on ASMG, we focus on information retrieval. Accordingly, we constitute the state of the art of this problem domain and outline future research directions.

关键词： Digital Manufacturing System Simulation Modeling Automation

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The development of a digital twin for machining processes for the application in aerospace industry

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Procedia CIRP 2020年 93卷 1399-1404页

作者： Albrecht Hänel Thorben Schnellhardt Eric Wenkler Andreas Nestler Alexander Brosius Christian Corinth Alexander Fay Steffen Ihlenfeldt Institute of Manufacturing Technology Technische Universität Dresden 01062 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU 01187 Dresden Germany Institute of Mechatronic Engineering Technische Universität Dresden 01062 Dresden Germany Institute of Automation Technology Helmut Schmidt University 22043 Hamburg Germany

This paper describes a method for creating a digital twin based on planning and process data for machining processes by using the example of components in the aerospace industry. This development is based on an information model that combines the properties and relationships of relevant information and data involved in the manufacturing process. This system integrates mathematical (technical-technological) models and algorithms for the determination of process parameters as well as planning-relevant information from the machining process. The technology of the digital twin makes it possible to recognize problems directly in the machining process, e.g. deviations from the planning specifications and to derive targeted measures for quality assurance and optimization of the machining process.

关键词： digital twin machining process information model process data aerospace

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Simulation-based digital twin for the manufacturing of thermoplastic composites

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Procedia CIRP 2021年 100卷 1-6页

作者： André Hürkamp Ralf Lorenz Tim Ossowski Bernd-Arno Behrens Klaus Dröder Technische Universität Braunschweig Institute of Machine Tools and Production Technology Langer Kamp 19b 38106 Braunschweig Germany Open Hybrid LabFactory Hermann-Münch-Straße 2 38440 Wolfsburg Germany Leibniz Universität Hannover Institute of Forming Technology and Machines An der Universität 2 30823 Garbsen Germany

The bond strength between a thermoformed fibre reinforced thermoplastic sheet and an injected polymer is the limiting factor for the structural integrity of overmoulded thermoplastic composites. In this contribution, a simulation based digital twin of the thermoforming process is presented. From numerical parametric studies a reduced order model based on Proper Orthogonal Decomposition (POD) is developed. The combination with machine learning methods enables the real-time computation of arbitrary physical reliable temperature fields with sufficient accuracy to be used for design purposes and as inline quality gates.

关键词： Thermoplastic Composites Thermoforming Finite Element Method Reduced Order Modelling Digital Twin

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Identification of Lack of Knowledge Using Analytical Redundancy Applied to Structural Dynamic Systems 1

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38th IMAC, A Conference and Exposition on Structural Dynamics, 2020

作者： Hartig, Jakob Hoppe, Florian Martin, Daniel Staudter, Georg Öztürk, Tugrul Anderl, Reiner Groche, Peter Pelz, Peter F. Weigold, Matthias Chair of Fluid Systems Technical University of Darmstadt Darmstadt Germany Institute for Production Engineering and Forming Machines Technical University of Darmstadt Darmstadt Germany Institute of Computer Integrated Design Technical University of Darmstadt Darmstadt Germany Institute of Production Management Technology and Machine Tools Technical University of Darmstadt Darmstadt Germany

ISBN: (数字)9783030476380

ISBN: (纸本)9783030487782

Reliability of sensor information in today’s highly automated systems is crucial. Neglected and not quantifiable uncertainties lead to lack of knowledge which results in erroneous interpretation of sensor data. Physical redundancy is an often-used approach to reduce the impact of lack of knowledge but in many cases is infeasible and gives no absolute certainty about which sensors and models to trust. However, structural models can link spatially distributed sensors to create analytical redundancy. By using existing sensor data and models, analytical redundancy comes with the benefits of unchanged structural behavior and cost efficiency. The detection of conflicting data using analytical redundancy reveals lack of knowledge, e.g. in sensors or models, and supports the inference from conflict to cause. We present an approach to enforce analytical redundancy by using an information model of the technical system formalizing sensors, physical models and the corresponding uncertainty in a unified framework. This allows for continuous validation of models and the verification of sensor data. This approach is applied to a structural dynamic system with various sensors based on an aircraft landing gear system. © 2020, The Society for Experimental Mechanics, Inc.

关键词： Redundancy

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Knowledge transfer and engineering methods for smart-circular product service systems

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Procedia CIRP 2021年 100卷 379-384页

作者： Friedrich Halstenberg Jasmin Dönmez Mark Mennenga Christoph Herrmann Rainer Stark Fraunhofer Institute for Production Systems and Design Technolog Pascalstr. 8-910587 Berlin Germany Institute of Machine Tools and Production Technology Chair of Sustainable Manufacturing and Life Cycle Engineering Technische Universität Braunschweig Langer Kamp 19 b 38106 Braunschweig Germany

Smart Product Service Systems (Smart PSS) have the potential to contribute to a Circular Economy (CE), but in the design of these systems engineering teams often lack information and knowledge on CE strategies and processes. Against this background, the authors propose a knowledge transfer system for the design of Smart-circular PSS. The system can be used in the concept phase of the Smart PSS development process and delivers information on CE strategies via a Smart-circular PSS Lifecycle Flowchart (SCPLF) and service archetypes. These strategies can be selected, supplemented and extended according to individual user requirements. The approach was validated using an intelligent street lighting system. This paper summarizes findings from the application and provides insights into potentials and limitations for the design of Smart-circular Smart PSS.

关键词： Smart PSS, Smart-circular PSS Model-based systems Engineering (MBSE) Sustainability

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Haptic feedback is more important than VR experience for the user experience assessment of in-car human machine interfaces 31st

Haptic feedback is more important than VR experience for the...

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31st CIRP Design Conference 2021, CIRP Design 2021

作者： Schölkopf, Lasse Lorenz, Mario Stamer, Mareike Albrecht, Lina Klimant, Philipp Hammer, Niels Tümler, Johannes Volkswagen AG Berliner Ring 2 Wolfsburg38436 Germany Professorship for Production Systems and Processes Chemnitz University of Technology Reichenhainer Straße 70 Chemnitz09126 Germany Department of Orthopedics Trauma and Plastic Surgery University Hospital Leipzig Liebigstraße 20 Leipzig04103 Germany Department of Macroscopic and Clinical Anatomy Medical University of Graz Harrachgasse 21 Graz8010 Austria Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Professur Ingenieurinformatik Anhalt University of Applied Sciences Bernburger Str. 55 Köthen06366 Germany

The user experience (UX) of a product is important for a customer's decision, especially in the automotive sector. In recent years, a frontloading of UX assessments from physical prototypes to virtual prototypes has occurred. Nevertheless, there are clear indications that established UX assessments methods cannot simply be transferred 1-to-1 from real to virtual evaluation setups as results get biased. For the UX assessment of an in-car human machine interface (HMI) the haptic properties of the knobs and buttons are just as important as their visual features. Therefore, it is mandatory to also simulate the haptic behavior of the in-car HMI in virtual reality (VR) assessment scenarios. However, accurately simulating this haptic behavior adds considerable costs and effort, diminishing the beneficial effects of VR UX assessments. Due to confidentiality reasons the volunteering participants of VR UX studies in the automotive sectors are typically employees with a varying degrees of VR experience. It is unknown if this gap in VR experience biases the results of UX assessments in VR. This paper presents a UX assessment study of an in-car HMI in VR in comparison to reality. From a practitioners viewpoint two research question are investigated: (1) How much is the UX assessment impaired by missing haptic simulation? (2) Does VR experience influence UX assessment ratings in VR? The results show that missing haptic feedback severely diminishes UX ratings, leaving no doubt that meaningful UX assessments in VR can only be performed when haptic is included. This means that more effort has to be put into earlier VR assessments severely reducing its benefits compared to UX assessments with physical prototypes. However, the VR experience of the participants only has a slight effect on the UX assessment results. © 2021 Elsevier B.V.. All rights reserved.

关键词： Virtual reality

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