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Zero-error-production through inline-quality control of presshardened automotive parts by multi-camera systems

IOP Conference Series: Materials Science and Engineering 2021年第1期1157卷

作者： A Pierer T Wiener L Gjakova J Koziorek Fraunhofer-Institute for Machine Tools and Forming Technology Chemnitz Germany VŠB - Technical University of Ostrava Faculty of Electrical Engineering and Computer Science Ostrava Czech Republic

Visual inspection often represents a bottleneck in the production chain due to limited receptivity and human fatigue. Depending on the inspection task, human classification error decisions greater than 10% are not uncommon. In order to make the manufacturing process more robust and sustainable, this paper presents innovative automated inline monitoring to realize a zero-error strategy in the field of industrial manufacturing. The central idea is to detect surface defects in the running production process by data fusion of a multi-camera system. Due to the required data analysis in conjunction with the targeted high throughput rates in production, this generates large amounts of data to process. Massively parallel hardware structures are used to enable defect detection within the production cycle. The paper especially addresses how to tackle boundary conditions in productive press-lines like the software-based mitigation of placement tolerances of parts and real-time capabilities. As a result, benefits could be achieved in terms of minimum detectable failure sizes and inspection speed, enabling 100% inline inspection of produced parts. The feasibility of the presented approach is demonstrated on realistic press-hardened deep-drawn automotive parts.

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Investigation of Waterjet Phases on Material Removal Characteristics

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Procedia CIRP 2020年 95卷 12-17页

作者： T. Bergs M. Schüler M. Dadgar T. Herrig A. Klink 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 52074 Aachen Germany

Abrasive waterjet (AWJ) controlled depth machining, often referred to as abrasive waterjet milling, 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 existing process models are limited and the jet tool consists of fluid-, solid- and gas-phases i.e. multiple physical processes occurring simultaneously. In this paper, the influence of the distinguished phases of waterjet machining on the material removal characteristics was investigated. In accordance with mechanical properties of the work piece, the process interference was considered at different structural modifications of 42CrMo4 steel, prior to processing and afterwards. With the help of different waterjet systems, the physical phenomena of the respective phases and their machining results were analyzed. Subsequently, a two-phase suspension jet containing water and solids and industry-standard 3-phase injector jet containing water, air and abrasives were used to machine a kerf pattern. Finally, a two-phase injection waterjet of sucking air without solids was used for post processing. A comparison was made by the geometrical features of the machining results. The applied understanding of the waterjet erosion process can lead to a better prediction and optimized waterjet results. Furthermore, the consequences may complete process models for simulation and support future applications of waterjet machining technique.

关键词： Abrasive waterjet machining Material modification Modeling

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Energy efficiency measures for metal forming using hydraulic and mechanical presses

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AIP Conference Proceedings 2024年第1期2989卷

作者： Mandy Preuß Gregor Thiele Jörg Krüger Ökotec Energiemanagement GmbH Torgauer Straße 12 Berlin Germany Fraunhofer IPK Institute for Production Systems and Design Technology Pascalstraße 8-9 10587 Berlin Germany Technical University of Berlin Institute for Machine Tools and Factory Management Pascalstraße 8-9 10587 Berlin Germany

In conventional hydraulic presses only around 13 percent of the energy supplied is converted into the plastic forming of the metal. Mechanical presses achieve an overall efficiency of 13 to 30 percent. A variety of approaches aspire efficiency improvements by tuning process parameters. For the operation engineers it is a crucial task to find measures which are both technical suitable and economical promising. This paper summarizes popular tuning parameters and presents the assessment by seven experts who participated in semi-structured interviews. For hydraulic presses, the most recommend tuning parameter to be adjusted is the pressing force. For mechanical presses the continuous stroke operation is the most popular measure.

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Improving dynamic process stability in milling of thin-walled workpieces by optimization of spindle speed based on a linear parameter-varying model

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Procedia CIRP 2020年 93卷 850-855页

作者： Semir Maslo Bruno Menezes Pascal Kienast Philipp Ganser Thomas Bergs Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany

In milling of thin-walled workpieces, like aero engine blades, the reduction of vibrations is of central importance to reach a more economical and reliable process as well as an improved workpiece surface quality. However, the dynamic behavior of the workpiece continuously varies due to changes in workpiece stiffness and mass, caused by the moving position of the excitation force as well as the material removal. In this paper, the simulation of the changing workpiece dynamics for a simplified blade geometry using FE-modal analysis is demonstrated. All extracted workpiece dynamic states are combined in a reduced LPV-model (Linear Parameter-Varying model). The LPV-model is able to describe the varying process dynamic behavior and makes the selection of advantageous spindle speeds possible.

关键词： process stability chatter vibration milling

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Influence of metal powder cross-contaminations on part quality in Laser Powder Bed Fusion: Copper alloy particles in maraging steel feedstock 11

Influence of metal powder cross-contaminations on part quali...

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11th CIRP Conference on Photonic Technologies, LANE 2020

作者： Horn, Max Langer, Lukas Schafnitzel, Mario Dietrich, Simone Schlick, Georg Seidel, Christian Reinhart, Gunther Fraunhofer Institute for Casting Composite and Processing Technology IGCV Am Technologiezentrum 10 Augsburg86159 Germany Department of Applied Sciences and Mechatronics University of Applied Sciences Munich Lothstr. 34 Munich80335 Germany Institute for Machine Tools and Industrial Management of Technical University of Munich Boltzmannstr. 15 Garching b. München85748 Germany

Metal powder cross-contaminations are a hindrance in powder-based additive manufacturing (AM). Foreign particles can enter the powder feedstock when two different materials are processed on a single machine - either successively through material changes or simultaneously during multi-material AM. In order to evaluate the criticality of named powder impurities, this study investigates the influence of foreign particle inclusions on part quality during laser powder bed fusion of a material combination commonly processed in multi-material AM: copper alloy CW106C particles in maraging steel 1.2709 feedstock. Different contamination levels are examined regarding metallurgical structure, defect formation, and mechanical strength. It is observed that coppery inclusions are dissolved and do not cause cracks, porosity or other defects below three particle percent. Furthermore, ultimate tensile strength and fracture elongation show a slight negative trend for increasing contamination levels. © 2020 The Authors. Published by Elsevier B.V.

关键词： 3D printers

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Tool System for UV induced micro moulding of biomedical disposables 18

Tool System for UV induced micro moulding of biomedical disp...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Edelmann, J. Gärtner, E. Eckert, U. Griebel, J. Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Leibnitz IOM Leipzig Germany

ISBN: (纸本)9780995775121

A new approach for the generation of double-sided microstructured polymer films is presented based on injection-molding of urethane- and epoxy-based acrylates that are polymerized by irradiation with ultraviolet light (395 nm). Compared to hot embossing, this offers not only working under ambient conditions, but also a reduction of cycle time as well as flexibility regarding adjustment of the mechanical and/or chemical properties of the resulting polyacrylate film. A setup, consisting of the mold with the microstructured insert and two LED lamps emitting UV-light moved by a controllable stepper motor and a computer-based controller, was installed and successfully used for the fabrication of double-sided microstructured polyacrylate films. Therefore a new and innovative tool system for 2-component UV induced micro moulding of biomedical disposables was developed. The geometrical dimensions of the microstructures (e.g. fins, channels, sharp edges and slopes) require different technologies to machine the tool inserts. Therefore micromilling and μ-laserablation technologies were used in combination attached by laser polishing operations in special areas. A highly precise, complex designed tool system with mechanically moveable areas is needed to fill the tool with the 2 various chemical compositions. The paper presents the tool concept and explains the investigated surface treatment options. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Micromachining

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Multi-material Additive Manufacturing: Metal Powder Recycling via Sedimentation

Multi-material Additive Manufacturing: Metal Powder Recyclin...

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European Powder Metallurgy Congress and Exhibition, Euro PM 2020

作者： Horn, Max van Betteraa, Jérôme Lederer, Frank Schafnitzel, Mario Dietrich, Simone Schlick, Georg Seidel, Christian Reinhart, Gunther Fraunhofer Institute for Casting Composite and Processing Technology IGCV Am Technologiezentrum 10 Augsburg86159 Germany Department of Applied Sciences and Mechatronics University of Applied Sciences Munich Lothstr. 34 Munich80335 Germany Institute for Machine Tools and Industrial Management Technical University of Munich Boltzmannstr. 15 Garching n. Munich85748 Germany

ISBN: (纸本)9781899072514

Powder-based multi-material additive manufacturing (AM) enables arbitrary material composition in parts. This opens new freedom of design possibilities for high-performance components. During multi-material AM however, processed powders get mixed and occurring cross-contaminations can lead to inferior part quality. Therefore, mixed powders need to be separated during recycling. As fluids generally increase selectivity of many sorting processes, this study investigates the possibility to apply a well-established fluid media-based sorting processes to recycle metal AM powder mixtures: sedimentation. Sink rates of four different, commonly processed metal alloys are examined experimentally. Furthermore, influence of fluid media on powder quality is discussed. For this purpose, non-corrosive fluids are selected - volatile hydrocarbons being most suiting. Concluding, the applicability of sedimentation as multi-material powder recycling solution is evaluated. © European Powder Metallurgy Association (EPMA)

关键词： Sedimentation

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Quantification of economic potential of 5G for latency critical applications in production

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Procedia Manufacturing 2020年 52卷 113-120页

作者： Raphael Kiesel Johannes van Roessel Robert H. Schmitt 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

A fourth industrial revolution has started with the objective of making the vision of highly efficient, connected and flexible manufacturing systems reality. Reliable communication systems being capable of handling several orders of magnitude the number of resources, diverse type of information and reaction times, will be the foundation of future manufacturing systems. The forthcoming 5G mobile communications standard appears to be an effective way to achieve a communication system for factories of the future. As wireless communication technology, 5G-technology can substantially reduce installation and maintenance costs while allowing to easily connect mobile or inaccessible devices and simplify line layout. Providing low latencies, high data transmission rates and the possibility of operating many devices simultaneously in narrowly restricted radio cells, 5G meets the demands of future manufacturing systems and has great potential to accelerate the ongoing digital transformation. Especially the characteristics of low latency (1 ms or less) and thus the possibility of monitoring and controlling complex production processes in near real-time hold a significant potential of 5G for manufacturing. Despite these prospected advantages, benefits of integrating 5G in a production process can barely be quantified yet. Current studies show that 40% of enterprises cite poor measurability of economic benefits of 5G for their specific processes as key concern. However, it is highly important to estimate these benefits before investing in such an elementary technology. This paper describes an approach for the quantification of economic potential of 5G for latency-critical applications in production. The core element of this approach is a framework of quantification criteria for the economic profitability of 5G technology based on production process parameters. This is mainly achieved by considering the improvements in product quality and process efficiency that are caused by usin

关键词： 5G-technology Latency Critical Production Processes URLLC Economic analysis Industrie 4.0 Networked adaptive production BLISK

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Fundamental research of applying tungsten carbide-cobalt as tool electrode material for sinking EDM

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Procedia CIRP 2020年 95卷 466-470页

作者： Eckart Uhlmann Mitchel Polte Robert Bolz Julian Börnstein Fraunhofer Institute for Production Systems and Design Technology Pascalstrasse 8-9 Berlin 10587 Germany Technische Universität Berlin Chair of Machine Tools and Manufacturing Technology Pascalstrasse 8-9 Berlin 10587 Germany

The manufacturing process milling is limited in machining specific geometries like inner contours with sharp edges, high aspect ratios or defined radii. Sinking EDM (S-EDM) is an appropriate process to machine complex features if the negative geometry is machinable. The tool electrode wear is a critical factor, because it affects machining accuracy and process efficiency. The tool electrode wear depends on S-EDM processing parameters, the geometry and material of the tool electrode. The material tungsten carbide-cobalt owns suitable thermophysical properties for the application as tool electrode material in EDM. Most applications of tungsten carbide-cobalt in EDM are limited to EDM drilling processes, where tungsten carbide tube electrodes are widely used. The advancements in milling of hard materials enable an economic manufacturing of tungsten carbide-cobalt form electrodes for sinking EDM applications. However, it is not investigated which composition of the material tungsten carbide-cobalt is the most appropriate for the application as tool electrode material in S-EDM. Additionally, there are no suitable EDM process parameters in order to benefit from the material characteristics of the respective tungsten carbide-cobalt. Focus of this work is the analysis of different tungsten carbide grades regarding the average grain size and the cobalt content in order to identify correlations between the material characteristics and the EDM process results. Therefore, eight different tungsten carbide grades with four different grain sizes and five different cobalt contents were applied in S-EDM experimental analysis. The experimental studies showed a general suitability of tungsten carbide-cobalt tool electrodes for EDM-processing, where the material removal rate is comparable to commonly used tool electrode materials. Nevertheless, the relative tool wear shows inferior results. It could be observed that higher cobalt content and coarser grain size of the applied tungsten c

关键词： EDM tungsten carbide-cobalt tool electrode

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A two-step digitalization level assessment approach for manufacturing companies

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Procedia Manufacturing 2021年 54卷 25-30页

作者： Günther Schuh Thomas Scheuer Gábor Nick Ádám Szaller Tamás Várgedő Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Aachen 52074 Germany Fraunhofer Institute for Production Technology Aachen 52074 Germany Széchenyi University Research Center of Vehicle Industry Győr 9026 Hungary EPIC InnoLabs Ltd. Budapest 1111 Hungary Institute for Computer Science and Control Budapest 1111 Hungary Department of Manufacturing Science and Engineering Budapest University of Technology and Economics Budapest 1111 Hungary

Manufacturing companies are facing the fourth industrial revolution, which concerns itself with the real-time data-based communication and connection between cyber-physical systems and people. To initiate a successful digital transformation, many organizations turn to Industry 4.0 maturity models for orientation and advice. This paper aims to enable companies to find the model that suits them best. Therefore, several existing models are introduced and two of them, a quick-assessment model ( CCMS ) and a more extensive approach ( Industry 4.0 Maturity Index ), are described in detail. These two complementing models are combined into a new resource-efficient approach to assessing Industry 4.0 maturity.

关键词： Industry 4.0 Maturity model Readiness assessment Digitalization

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