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Life Cycle Engineering of future aircraft systems: the case of eVTOL vehicles

Procedia CIRP 2020年 90卷 297-302页

作者： Sofia Pinheiro Melo Felipe Cerdas Alexander Barke Christian Thies Thomas S. Spengler Christoph Herrmann Institute of Machine Tools and Production Technology (IWF) Chair of Sustainable Manufacturing and Life Cycle Engineering Technische Universität Braunschweig Germany Battery LabFactory Braunschweig (BLB) Technische Universität Braunschweig Germany Institute of Automotive Management and Industrial Production Technische Universität Braunschweig Braunschweig Germany Fraunhofer Institute for Surface Engineering and Thin Films (IST) Germany

This paper introduces the first steps towards a general modelling framework for the integrated life cycle engineering (LCE) of future air transportation systems. The focus of analysis lies on the potential environmental implications of batteries powering electric vertical takeoff and landing aircrafts (eVTOLs), which have emerged as an option for urban air mobility to alleviate automobile traffic in cities. The impact of main influencing factors on the sustainability of eVTOLs is discussed, presenting the main modelling requirements for an LCE framework to accompany the transition towards a more sustainable air mobility.

关键词： Life Cycle Engineering Aviation VTOLs Batteries

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Transferring life cycle engineering to surface engineering

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Procedia CIRP 2020年 90卷 557-562页

作者： Alexander Leiden Peter-Jochen Brand Felipe Cerdas Sebastian Thiede Christoph Herrmann Chair of Sustainabel Manufacturing and Life Cycle Engineering Institut of Machine Tools and Production Technology (IWF) Technische Universität Braunschweig Langer Kamp 19b 38106 Braunschweig Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Bienroder Weg 54 e 38108 Braunschweig Germany

Most surface finishing processes for metals are associated with a high energy demand and the use of chemicals with the potential impact on human- and eco-toxicity. However, surface finishing processes can lead to environmental and economic benefits in other life cycle phases by reducing friction, wear and corrosion. The application of life cycle engineering into surface engineering allows to understand these effects. This study provides a framework to assess environmental and economic effects of surface treatments on other life cycle phases. A case study illustrates the contribution of a surface finishing process for cutting inserts to the life cycle performance.

关键词： Life cycle engineering Surface engineering Sustainability

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Bio-inspired control of automated stem cell production

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Procedia CIRP 2020年 88卷 600-605页

作者： Péter Egri Balázs Cs. Csáji Krisztián B. Kis László Monostori József Váncza Jelena Ochs Sven Jung Niels König Robert Schmitt Christian Brecher Simon Pieske Stephan Wein Centre of Excellence in Production Informatics and Control Institute for Computer Science and Control Kende u. 13-17 Budapest 1111 Hungary Fraunhofer Institute for Production Technology Steinbachstr. 17 Aachen 52074 Germany Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Campus-Boulevard 30 Aachen 52074 Germany

The possible role of stem cells in medical treatments can hardly be overestimated. Today they are produced – almost without exemption – with significant human involvement using adaptive protocols that take the growth behavior of the biological material into account. Automated production platforms are being developed and tested in a number of research laboratories with the main goals of improving reproducibility, as well as increasing quality and throughput. However, automated stem cell production differs from the traditional manufacturing processes in (1) the inherent diversity of the products (stem cells), (2) their varying growth rates and process times, (3) the need for their regular observation and process adaptation, and, therefore, (4) for mixed-initiative production control. A distinctive feature of the domain is the symbiotic co-existence and co-evolution of the technical, ICT and biological ingredients in production structures. A challenging way to overcome these issues is the use of biologically-inspired control algorithms. In the paper the application of reinforcement learning is proposed for this purpose. As a first step, a digital simulation of the stem cell production was performed in order to generate patterns for the training process and to test the approach. In addition to the description of the concept, the paper also presents initial research results.

关键词： Stem cell production Digital simulation machine learning Reinforcement-based control Biological transformation

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Effects of process interruptions on the microstructure and tensile properties of AlSi10Mg parts manufactured by Laser-Based Powder Bed Fusion

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Procedia CIRP 2020年 94卷 182-187页

作者： Maximilian Binder Cheechau Leong Christine Anstaett Georg Schlick Christian Seidel Gunther Reinhart Fraunhofer IGCV (Research Institute for Casting Composite and Processing Technology) Am Technologiezentrum 10 86159 Augsburg Germany Department of Applied Sciences and Mechatronics University of Applied Sciences Munich Lothstr. 34 80335 Munich Germany Technical University of Munich Institute for Machine Tools and Industrial Management Boltzmannstr. 15 85748 Garching Germany

During the metal-based additive manufacturing process “laser-based powder bed fusion” (short: PBF-LB/M) interruptions can occur throughout the build job. These interruptions may be planned to produce hybrid parts, e.g., to insert components or electronics into the part or to adapt the manufacturing process itself. But interruptions can also be fault-induced, which can occur due to system failures, insufficient available powder quantities or poor component and process characteristics. Depending on duration, temperature and ambient atmosphere, these interruptions can have major influences on the component’s properties. The effects of a process interruption on the microstructure and the tensile properties for the material AlSi10Mg are to be presented within this work. In addition the impact of process interruptions on the mechanical properties of the tested components is shown.

关键词： process interruptions change of microstructure tensile properties additive manufacturing metal laser-based powder bed fusion

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Incremental sheet metal forming on the example of car exterior skin parts

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Procedia Manufacturing 2019年 29卷 105-111页

作者： Sören Scheffler Alexander Pierer Peter Scholz Sebastian Melzer Dieter Weise Zdeněk Rambousek Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany VÚTS a.s. Svárovská 619 Liberec XI-Růžodol I 460 01 Liberec Czech Republic

In this article, current, application-related investigations in the field of incremental sheet metal forming (ISF) will be presented and discussed. The main focus of the study will be on the chain of conceptual design, experimentation and subsequent work processes, right through to the final assembly of car exterior skin parts of a streamlined vintage concept car. This will be accompanied by a comparison and evaluation of different production technologies with regard to their economic efficiency, their real duration times and the specific boundary conditions for the manufacturing of just one part per geometry. The manufacturing processes at the centre of the study were: deep drawing, hydroforming and ISF (Two Point Incremental forming (TPIF) and rolling). Following the holistic discussion on the procedure and choice of processes, the TPIF is examined in detail using the example of the rear mudguards.

关键词： Incremental Sheet Metal forming Two Point Incremental forming Sheet Metal forming forming machine Design

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Modeling energy and resource use in additive manufacturing of automotive series parts with multi-jet fusion and selective laser sintering

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Procedia CIRP 2021年 98卷 358-363页

作者： Mathias Wiese Alexander Leiden Christopher Rogall Sebastian Thiede Christoph Herrmann Polymer Additive Manufacturing Center AUDI AG Auto-Union-Straβe 1 Ingolstadt 85045 Germany Chair of Sustainable Manufacturing and Life Cycle Engineering Institute of Machine Tools and Production Technology Technische Universität Braunschweig Langer Kamp 19b Braunschweig 38106 Germany Chair of Manufacturing Systems Department Design Production and Management University of Twente Drienerlolaan 5 Enschede 7522NB The Netherlands Fraunhofer Institute for Surface Engineering and Thin Films (1ST) Bienroder Weg 54 E Braunschweig 38108 Germany

With additive manufacturing (AM) becoming a competitive manufacturing process for low to medium production volumes, rapid manufacturing becomes an increasingly relevant manufacturing approach. However, regulations and customers demand more eco-efficient life-cycles of products. This requires engineers and designers to pre-select between productive AM processes like selective laser sintering (SLS) and multi-jet fusion (MJF), based on their expected environmental impact in series production. As SLS already debuted in the mid-1980s, researches broadly explored parts’ mechanical properties, energy and resource use. The multi-jet fusion (MJF) technology, introduced in 2017, delivers comparable part properties at considerably higher print speeds. However, its energy and resource use is still scarcely covered. To close this gap, this publication develops a model for evaluation of energy and resource utilization based on a case study with an automotive exterior series part using an EOS P396 SLS and a HP 4200 MJF machine. Data from measurements in energy and material consumption as well as the print job shows a good predictability and builds the basis for an environmental assessment. The derived model and its functional blocks allow estimation and comparison of sustainability for different use cases in rapid manufacturing with MJF and SLS. Despite the process similarities, results concerning greenhouse gas emissions and cumulative energy demand are different. The gained insights enhance pre-selection of manufacturing strategies, a suitable printing technology and the evaluation of AM processes during manufacturing according to sustainability aspects. Printer manufacturers and users may find this research insightful for improvements in sustainability and comparability of future AM processes.

关键词： Rapid manufacturing Energy efficiency Resource efficiency Additive manufacturing Automotive engineering Process modeling

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Wishbone made of hybrid aluminum foam sandwich

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Lightweight Design worldwide 2018年第2期11卷 36-41页

作者： Claudia Drebenstedt Camilo Zopp Alexander Hackert Lothar Kroll Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany TU Chemnitz Germany

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On the Selection and Application of a Convenient Energy Management Software for Industrial Purposes

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IOP Conference Series: Materials Science and Engineering 2021年第1期1140卷

作者： Larissa Wurster Gregor Thiele Clemens Briese Jörg Krüger Plant Development Infrastructure / Assembly Trucks (TG/MAD) Daimler Truck AG Department for Process automation and Robotics Fraunhofer Institute for Production Systems and Design Technology Department for Machine Vision Fraunhofer Institute for Production Systems and Design Technology Department for Industrial automation at the Institute for Machine Tools and Factory Management Technical University of Berlin

The profitability of companies, especially in Germany, is affected by rising energy prices and increasingly stringent energy legislation. Certification according to ISO 50.001, an international standard for energy management systems, can help to meet legal requirements and increase energy efficiency. This article offers assistance in the form of a methodology that provides a structure for the selection process of an energy management system (EnMS). Considering properties of the individual company, it helps to identify an appropriate software solution. It is applied to a globally operating metalworking company in an example study. Furthermore, the measurement infrastructure in particular is a basic requirement that should not be overlooked in addition to the process of choosing an appropriate software solution. In this context, suitable metering points or criteria must be defined as well as sufficient attention paid to the anticipated costs for acquiring and integrating new measuring transducer and energy meters. The type and number of relevant measuring points must be considered in particular. Discussing these aspects, this article facilitates the process of planning and implementing an energy monitoring.

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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

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Procedia CIRP 2020年 94卷 167-172页

作者： Max Horn Lukas Langer Mario Schafnitzel Simone Dietrich Georg Schlick Christian Seidel Gunther Reinhart Fraunhofer Institute for Casting Composite and Processing Technology IGCV Am Technologiezentrum 10 86159 Augsburg Germany Department of Applied Sciences and Mechatronics University of Applied Sciences Munich Lothstr. 34 80335 Munich Germany Institute for Machine Tools and Industrial Management of Technical University of Munich Boltzmannstr. 15 85748 Garching b. München 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.

关键词： multi-material additive manufacturing powder quality powder purity foreign particles cross-contamination recycling reuse

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Structural loading of cellular metals: Damage mechanisms and standardization concepts 10th

Structural loading of cellular metals: Damage mechanisms and...

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10th International Conference on Porous Metals and Metallic Foams, MetFoam 2017

作者： Krupp, Ulrich Hipke, Thomas Nesic, Srecko Institute of Materials Design and Structural Integrity University of Applied Sciences Osnabrück Osnabrück49009 Germany Fraunhofer Institute of Machine Tools and Forming Technology IWU Chemnitz09126 Germany

ISBN: (纸本)9783035712315

Structural loading of cellular metals is strongly affected by brittle fracture of cell struts and walls that exhibit tensile loads, e.g., during fatigue loading. The present paper summarizes results of compression, tension and cyclic loading experiments on various closed-cell metal foams and metal foam sandwiches (Alulight, Alporas, Foamtech, AFS) using various mechanical testing systems. The results were correlated with a thorough analysis of the cellular mesostructure and the cell strut/wall microstructure by means of scanning electron microscopy revealing defects, such as casting porosity and large Si precipitates in the Al-Si eutectic of aluminum cast alloy. The results of the work served for the definition of testing standards for compression testing (ISO 13314) and tensile testing (DIN 50099), which are outlined in the paper. Such standards and design guidelines are crucial for a successful implementation of cellular metals in innovative products in mechanical, automotive and energy engineering as well as in bioengineering. © 2018 Trans Tech Publications, Switzerland.

关键词： Tensile testing

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