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Time- and Cost-Efficient Specification and Evaluation of Manufacturing Changes through Iterative Information Acquisition

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Procedia CIRP 2021年 104卷 176-181页

作者： L. Hermann A. Weber A. Beckers S. Barth T. Bergs Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany FH Aachen University of Applied Science Bayernallee 11 52066 Aachen Germany Fraunhofer Institute for Production Technology Steinbachstraße 17 52074 Aachen Germany

The adaptation of established products and their components is a crucial process for companies to react to changing environments. To realize a component change, the corresponding manufacture must also be adapted. Often, a specific component change can be realized through alternative Manufacturing Changes, which must be specified and evaluated in relation to one other. A systematic approach to a timely and cost-efficient specification and evaluation of alternative Manufacturing Changes is therefore presented in this paper. The approach is based on an iterative information acquisition process, which generates the input for the specification and evaluation of Manufacturing Changes.

关键词： Manufacturing Change Management technology Planning Manufacturing Adaptation

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Thermal errors in milling: Comparison of displacements of the machine tool, tool and workpiece

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Procedia CIRP 2019年 82卷 389-394页

作者： M. Putz J. Regel A. Wenzel M. Bräunig Chemnitz University of Technology 09010 Chemnitz Germany Fraunhofer-Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany

The paper describes an experimental method for quantifying the proportions of thermal errors of the machine tool, tool and workpiece in the total thermal error. For this purpose, the workpiece was subsequently measured and both the machine-internal and additionally built-in measuring sensors were used to quantify displacement errors. The static errors must also be detected. Based on the measured values, thermal states are calculated by regression analysis and included in the evaluation. The percentages of the single errors were calculated and gave a clear statement about the time sequences and the thermal influence of the components regarding to the total error in a milling process. The results allow an assessment of relevant areas that contribute to positioning errors.

关键词： experimental investigation thermal error machine tools milling

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Influence of heat treatment on the residual stress-related machining distortion of Ti-6Al-4V alloy monolithic parts

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Procedia CIRP 2021年 104卷 1328-1333页

作者： M. Landwehr F. Oehler H. Behnken H. Holling R. Sambathkumar P. Ganser T. Bergs Fraunhofer Institute for Production Technology IPT Steinbachstrasse 17 52074 Aachen Germany ACCESS e.V. Intzestraße 5 52072 Aachen Germany Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus Boulevard 30 52074 Aachen Germany

Machining distortion caused by residual stresses is one of the major challenges in the production of thin-walled monolithic parts. One reason for the distortion is the relaxation of the initial residual stresses within the raw part due to the material removal during the machining process. The initial residual stresses mainly depend on the manufacturing process of the raw part and the subsequent heat treatment. This paper presents the results from a set of experimental and computational studies of the influence of heat treatment on residual stress-related machining distortion of Ti-6Al-4V alloy monolithic parts. A thermo-mechanical simulation of the heat treatment process is developed for the prediction of the initial residual stresses. For experimental validation, the contour method is used to quantify the initial residual stresses. Finally, machining tests are conducted to measure the final part distortion for two different residual stress states.

关键词： Machining distortion Residual stress Milling Ti-6Al-4V alloy Heat treatment Thermo-mechanical simulation Monolothic parts Contour method

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Increasing flexibility of self-pierce riveting using numerical and statistical methods

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Procedia Manufacturing 2019年 29卷 264-270页

作者： Tobias Falk Mathias Jäckel Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 01187 Dresden Germany

Self-pierce riveting with semi-tubular rivets (SPR-ST) is currently the most important joining technology for modern mixed-material car body constructions. In these body designs a multitude of material and thickness combinations occurs and for many of these combinations individual parameters of the SPR-ST process like the rivet length and die geometry have to be determined. This paper shows an approach to increase the flexibility of the SPR-ST process by the determination of the process parameters using FEM simulations in combination with statistical methods. In the described investigations one parameter set is derived for the SPR-ST process from seven different material combinations with steel and aluminum materials. For each material combination a simulation model is validated by the comparison of the joint geometry and force-stroke diagram from the experimental reference joints with the results from the process simulation. On the basis of the validated simulation models, numerical sensitivity analyses are carried out for each material combination to investigate the correlations between the process parameters die geometry and rivet length with important quality characteristics of the joint like interlock, minimal thickness of the die-sided sheet and joining force. With the knowledge of these studies computed process optimizations are carried out, in order to define one die geometry to join all seven material combinations in good quality, so a tool changing is no longer required. The reduction from seven to only one optimized SPR-ST tool saves costs as well as processing time and production space.

关键词： Self-pierce riveting Sensitivity analyses Tool optimization

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Concept for a modular system model for energy-efficiency monitoring of factory supply systems

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AIP Conference Proceedings 2024年第1期2989卷

作者： Stefan Sigg Gregor Thiele Marvin Trapp Jörg Krüger Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany Institute for Machine Tools and Factory Management Technische Universität Berlin Pascalstr. 8-9 10587 Berlin Germany

Companies in the manufacturing industry are facing the challenges of both reducing energy costs as well as driving decarbonization. As a result, energy efficiency optimization of factory operations is gaining importance. Due to their high share in the energy consumption of a factory, industrial supply technology is of interest for these optimizations. Particularly cooling systems used in factories often offer considerable potential for energy efficiency improvements, some of which can be realized through optimized control strategies. Optimization based on control technology in particular requires a high level of energy consumption transparency in order to identify potentials and measure efficiency improvements. However, industrial supply systems are often complex and interconnected facilities composed of a combination of various individual assets. Consequently, the energy efficiency monitoring and analysis of such systems typically require a high manual effort. To reduce this effort, we propose the development of a modular system model which decomposes complex, interconnected energy systems to individual, recurring assets. The system model consists of a standardized data exchange format, a standardization of structural and behavioral models in the form of a model library for industrial supply systems at different hierarchy levels, and a standardized interface for using the data model on a target platform such as an energy management software. The data model of the data exchange format maps data points such as the control and media interfaces as well as energy performance indicators of the individual assets in a standardized and consistent way. Similar to the concept of digital twins, the knowledge of manufacturers and operators about the system is to be seamlessly combined and utilized. By connecting the interfaces of the individual asset models, an aggregate structural model of a factory supply system is built. The aggregate structural model enables the calculation

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Modeling of the wet immersed tumbling process with the Discrete Element Method (DEM)

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Procedia CIRP 2021年 102卷 1-6页

作者： E. Uhlmann J.-P. Fürstenau Y. Kuche S. Yabroudi J. Polte M. Polte Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 Berlin 10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin 10587 Germany CADFEM GmbH Pelikanstr. 13 Hannover 30177 Germany

Immersed tumbling is an industrially established process for finishing of components made of metal, ceramic or plastic. In this process, the components are completely surrounded by a wet, abrasive medium, which allows burrs to be removed and surfaces to be polished. In order to gain specific insights into the influence and flow properties of the abrasive media used in this process, numerical approaches using the Discrete Element Method (DEM) with the Rocky DEM software are presented within these investigations. A complete process simulation could be realised by means of a digital machine tool. The immersed tumbling process with cone-shaped polymer abrasive media is implemented by use of a liquid bridge model. The results were validated by experiments with an industrially used immersed tumbling machine tool and for the first time allow sound statements about the contact conditions and interactions of the abrasive media with the workpiece.

关键词： discrete element method DEM immersed tumbling liquid bridge facetted particles

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Process development for self-pierce riveting with solid formable rivet of boron steel in multi-material design

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Procedia Manufacturing 2019年 29卷 271-279页

作者： Thomas Grimm Welf-Guntram Drossel Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 01187 Dresden Germany

Mechanical joining techniques are important joining processes for the implementation of lightweight structures in automotive engineering and other branches of industry. However, existing processes such as self-pierce riveting with semi-tubular rivet (SPR-ST) or solid rivet (SPR-S) reach their limits in certain applications, e.g. joining press-hardened boron steel sheets in multi-material constructions of automotive bodies. A new method to join these materials reliably and with high quality is the self-pierce riveting with solid formable rivet (SPR-SF). This paper shows different problems during the mechanical joining of press-hardened steel 22MnB5 by conventional SPR-S and illustrates the numerical as well as the experimental development of the new rivet concept: the solid formable rivet. On the basis of validated simulation models for conventional SPR-S numerical sensitivity analyses are carried out to investigate the correlations between the rivet properties (geometry parameters, material) and important quality characteristics of the joint like interlock, punching force and upsetting force for the new SPR-SF joining process. With the knowledge of these studies, specific rivet geometries are determined and prototypes manufactured for joining the material combination EN AW-6016 T4 ( t = 1.5 mm) into 22MnB5 ( t = 1.2 mm) in good quality. So, the application potential of the new SPR-SF is shown.

关键词： Self-pierce riveting Sensitivity analysis Boron steel Multi-material joining technology

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Guideline for Deployment of machine Learning Models for Predictive Quality in Production

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Procedia CIRP 2022年 107卷 815-820页

作者： Henrik Heymann Alexander D. Kies Maik Frye Robert H. Schmitt Andrés Boza Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen 52074 Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 Aachen 52074 Germany Centro de Investigación Gestión e Ingeniería de la Producción (CIGIP) Universitat Politècnica de València Camino de Vera s/n Valencia 46022 Spain

Predicting product quality represents a common area of application of machine learning (ML) in manufacturing. However, manifold challenges occur during the integration of ML models into production processes. Therefore, this paper aims to provide a guideline for the deployment of ML models in production environments. Relevant decisions and steps for deploying models in predictive quality use cases are demonstrated. The results for each component of the proposed guideline - deployment design, productionizing & testing, monitoring, and retraining - have been validated with industry experts including exemplary implementations.

关键词： Artificial Intelligence machine Learning Deployment Production Manufacturing Predictive Quality

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Resource-efficient, innovative coil production for increased filling factor

Resource-efficient, innovative coil production for increased...

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International Electric Drives Production Conference (EDPC)

作者： Maik Linnemann Mirko Bach Verena Psyk Markus Werner Marcel Gerlach Nadine Schubert Fraunhofer- Institute of Machine Tools and Forming Technologies Chemnitz Germany

ISBN: (数字)9781728143194

ISBN: (纸本)9781728143200

Due to new requirements regarding the efficiency of electrical machines it is necessary to increase the slot filling factor of such machines. forming technology offers an excellent opportunity to achieve this aim. The paper therefore presents a method for flexibly adapting the cross-sectional shape of the coil to the geometry of the slot. First, the potentials and limits of forming technologies are presented. Furthermore, the forming tool required for the cross-sectional adaptation is described. Advantages and limits of the method are analyzed and evaluated. In particular, factors such as elongation and burr formation play a decisive role here. Finally, an outlook is given and possible research approaches are discussed.

关键词： Wires Filling Windings Shape Pressing tools Presses

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Beyond Model-Based Systems Engineering towards Managing Complexity 30

Beyond Model-Based Systems Engineering towards Managing Comp...

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30th CIRP Design on Design, CIRP Design 2020

作者： Masior, Jonathan Schneider, Benjamin Kürümlüoglu, Mehmet Riedel, Oliver Fraunhofer Institute for Industrial Engineering IAO Nobelstrasse 12 Stuttgart70569 Germany University of Stuttgart Institute for Human Factors and Technology Management IAT Nobelstrasse 12 Stuttgart70569 Germany University of Stuttgart Institute for Control Engineering of Machine Tools and Manufacturing Units ISW Seidenstrasse 36 Stuttgart70174 Germany

Systems Engineering domain lacks in methodologies for integration of development artefacts (e.g. requirements, functions, geometrics, or behavior) and enterprise models (e.g. organizational structures, processes, or IT infrastructure). Especially the rising complexity driven by integrated product service systems, smart services, systems of systems and cyber physical systems (CPS) leads to a new paradigm further on called Advanced Systems Engineering (ASE). It empowers enterprises to cope with such complex developments. The employment of ASE technologies in design and manufacturing enterprises requires a reachability of technical information and continuity along vertical and horizontal dimensions. A widely used approach to implement this is Model-based System Engineering (MBSE). This paper introduces a solution to achieve the goals of manufacturing excellence as well as complexity management by identifying and analyzing relevant requirements and possible approaches for an innovative simulation enabling and executable modelling language, the so-called advanced MBSE+. © 2017 The Authors. Published by Elsevier B.V.

关键词： Cyber Physical System

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