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13th International DAAAM Baltic Conference and 29th International Baltic Conference, BALTMATTRIB 2021

作者： Wolff, Tobias Vick, Axel Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin Germany

Nowadays, manufacturers face the problems to adjust their production according to the fast-changing global competition. Car manufacturers, for example, are in front of a new era of individual mobility. They need to switch from combustion engines to electric drives. In general, manufacturers have to develop production strategies to lower set up time and meet requirements faster. The classical production line is most effective if the product variety is low and the lot size is high but facing the rapid growing demand for individualized products and fast-changing requirements, manufacturers must discover new ways of manufacturing. One possibility is the flexible shopfloor. In this work, we will present our concept of a flexible shopfloor IT for controlling a robotic demonstrator. We use OPC UA over TSN as a platform for communication and CODESYS as SoftSPS for the control of sensors and actuators. In order to create valid data for ongoing discussions we use function point analysis and counting lines of sourcecode to measure software size. Our expectation is that the initial effort for implementing a flexible shopfloor IT is higher compared to the classic approach, but for all the following implementation it will take less time, because of the possibility of reuse already developed systems. © 2021 DAAAM International. All rights reserved.

关键词： Electric drives

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PRECISION FINISHING OF ADDITIVE MANUFACTURED Ti-AI-COMPONENTS USING DIAMOND SLIDE BURNISHING

PRECISION FINISHING OF ADDITIVE MANUFACTURED Ti-AI-COMPONENT...

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2022 ASPE and euspen Summer Topical Meeting on Advancing Precision in Additive Manufacturing

作者： Polte, Julian Polte, Mitchel Lahoda, Christian Uhlmann, Eckart Fraunhofer Institute for Production Systems and Design Technology IPK Technische Universitat Berlin Berlin Germany Institute for Machine Tools and Factory Management IWF Technische Universitat Berlin Berlin Germany

ISBN: (纸本)9781713859192

Due to the increasing importance of lightweight design in terms of resource management, titanium aluminium (Ti-AI) alloys are gaining more and more significance. To fully exploit light weight design potentials additive manufacturing (AM) has the ability to shift state of the art product design towards maximised resource efficiency and physically minimized weight. Next to material standardization and qualification processes, major limitations for mass scale industrialization of additive manufacturing are high surface roughness values in a range of 5 μm ≤ Ra ≤ 15 urn and remaining tensile residual stress states. A promising approach to overcome these challenges shows a process chain consisting of near-net-shape laser powder bed fusion (LPBF) and subsequent finishing using a dedicate diamond slide burnishing (DSB) process [1]. Within this work plastic deformation induced by DSB and the effects on the workpiece material properties were investigated. Copyright© (2022) by American Society for Precision Engineering (ASPE) All rights reserved.

关键词： Surface roughness

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Inductive heating based on VHF-ISM radio band frequencies as technology platform for efficient heating of metallic micro-scaled bonding layers in MEMS packaging

Inductive heating based on VHF-ISM radio band frequencies as...

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2023 IEEE International Magnetic Conference - Short Papers, INTERMAG Short Papers 2023

作者： Hofmann, Christian Kroll, Martin Panhale, Sushant Wiemer, Maik Kunke, Andreas Hiller, Karla Kuhn, Harald Fraunhofer Institute for Electronic Nano Systems Enas Chemnitz09126 Germany University of Technology Institute for Machine Tools and Production Processes Chemnitz09126 Germany University of Technology Center for Microtechnologies Chemnitz09126 Germany

ISBN: (纸本)9798350338362

This paper presents a method for selective and energy-efficient induction heating of metallic microstructures to support and enhance metal bonding technologies for MEMS packaging. The technological challenges include the use of miniaturized coils for homogeneous heat distribution, the implementation of VHF-ISM radio band frequencies up to f0 = 40.68 MHz for the generation of high frequency electromagnetic fields and the integration of the inductive equipment into a heating and bonding system. FE simulation and infrared (IR) thermography were used to characterize the inductive process with low coil currents of I0 © 2023 IEEE.

关键词： MEMS

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End-of-life decision support to enable circular economy in the automotive industry based on digital twin data 33

End-of-life decision support to enable circular economy in t...

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33rd CIRP design Conference

作者： Mügge, Janine Hahn, Inka Rebekka Riedelsheimer, Theresa Chatzis, Johannes Boes, Joachim Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany TEC4U-Ingenieurgesellschaft MbH Saar-Lor-Lux-Straße 15 Saarbrücken66115 Germany

With the EU Green Deal and the UN Sustainable Developments Goals, the vision of a greenhouse gas-neutral and resource-efficient economy is already firmly anchored in world politics. In this context, the automotive industry faces many challenges including the increasing scarcity of natural resources, a rising demand in terms of sustainable vehicle design, production and materials sourcing. Due to all this, end-of-life decisions regarding dismantling have become increasingly important. A high proportion of secondary materials will be required in the vehicles of the future. To response to these challenges, companies have turned their focus towards the circular economy as a central approach to close material loops. In the German research project "Catena-X" a new data ecosystem with digital twins is one enabler that is being developed. The digital twins represent a promising approach to the circular economy by ensuring transparent, product-specific and end-to-end data exchange throughout the entire product lifecycle, from the material sourcing to the eventual dismantling and recycling. As one particular and unique solution, a decision framework that facilitates the best circular strategy at the end of a vehicle's life is developed and presented in this paper. The underlying data-driven decision support framework is based on circular economy KPIs. This includes material, components and specific vehicle KPIs to best identify the most suitable circular strategy. The framework was methodologically developed by an interdisciplinary team of partners, who are stakeholders throughout the value chain and participants in the Catena-X project. An integrated approach of user-centered design, an adapted version of the V-model and the Scaled Agile Framework were used for the methodology in the development of the solution. The paper presents the concept of a digital twin for a decision support system, that includes a central decision logic that also includes the relevant KPIs and a sur

关键词： Sustainable development

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Residual stresses in additive manufactured precision cemented carbide parts 22

Residual stresses in additive manufactured precision cemente...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Polte, J. Polte, M. Hocke, T. Blankenburg, M. Lahoda, C. Uhlmann, E. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Deutsches Elektronen-Synchrotron DESY Germany

ISBN: (纸本)9781998999118

Due to the good strength properties and high hardness, components made of cemented carbide are used in various industrial sectors as key components, e.g. mould making and matrices. Precision cemented carbide parts are mainly machined by milling and electrical discharge machining (EDM). Nevertheless, long machining times and excessive tool wear are remaining challenges at the state of the art. A promising approach to overcome these challenges is the machining of precise cemented carbide parts using a process chain consisting of near-net-shape laser powder bed fusion (LPBF) and subsequent finishing using a dedicate diamond slide burnishing process. Within previous investigations a geometrical accuracy of ag= 10 µm and a reduction of the surface roughness by Ra = 89 % could be achieved. Within this work plastic deformation induced by the diamond slide burnishing and the effects on the material properties in the surface area were investigated, e.g. residual stresses. For this purpose, the lattice distortion of the metallic cobalt phase was measured by X-ray diffraction using high-energy synchrotron radiation. In addition, the height profile of the residual stresses was also recorded in distances of d = 3 µm to obtain information about the depth effect of the diamond slide burnishing process. Based on the investigations an increase of the residual compressive stresses could be obtained. This shows a particularly positive effect especially for additively manufactured components, as these often show a slight porosity and higher surface roughness as conventional manufactured components. In this way, crack propagation can be prevented and the fatigue strength can be increased. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Residual stresses

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Evolving Roles in systems Engineering —- Insights from Germany's Mechanical and Plant Engineering Sector

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INCOSE International Symposium 2024年第1期34卷 1413-1428页

作者： Kaiser, Lydia Wilke, Daria Förster, Felix Köhler, Ingmarie Dumitrescu, Roman Technische Universität Berlin and Einstein Center Digital Future Berlin Germany Fraunhofer Research Institute for Mechatronic Systems Design IEM Paderborn Germany Hamburg University of Technology Institute of Smart Engineering and Machine Elements Hamburg Germany Technische Universität Berlin Berlin Germany

systems Engineering is developing differently in each sector and region. In German industry, especially in mechanical and plant engineering, systems Engineering is of major importance. The introduction of systems Engineering raises the question of which roles and competencies are required. This article examines the evolution of roles in systems Engineering from a German perspective. Based on a literature review, the evolution of the identified systems Engineering roles over time is shown, starting with the seminal publication by Sheard in 1996. It points out that only minimal adjustments and occasional role renaming have occurred. However, the review shows a common understanding of essential areas of responsibility within the SE and changes over time. The next step is to examine the current understanding of systems Engineering roles in the industry. A quantitative analysis of job postings in Germany reveals a diverse interpretation of the term 'systems Engineer;more than half of the positions cannot be categorized according to the INCOSE definitions. The job postings are used to determine which tasks are associated with the job, how often they occur, and in what combination. The primary responsibilities of systems engineers include creating and managing requirements, architecture processes, validation, and verification processes, and coordinating with customers and stakeholders. Finally, three representative companies from the mechanical and plant engineering sector were selected to analyze existing roles and tasks. From this, a common understanding of tasks and responsibilities is combined and organized into clusters. These are used by the companies to locate and thus derive their roles. The result is in an integrative approach that enables companies, especially in the midsize and medium sectors, to design the introduction in line with stakeholder demands. In summary, the industry's ongoing adaptation necessitates the evolution of systems Engineering roles and comp

关键词： systems Engineering Roles German Industry Role Evolution Competencies Job postings Literature Review

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Numerical study on the temperature characteristic of material absorptivity and its significance in high-power laser beam welding 13

Numerical study on the temperature characteristic of materia...

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13th CIRP Conference on Photonic Technologies, LANE 2024

作者： Putra, Stephen Nugraha Meng, Xiangmeng Yang, Fan Bachmann, Marcel Rethmeier, Michael Bundesanstalt for Materialforschung und -Pröfung Unter den Eichen 87 Berlin12205 Germany Technical University Berlin Institute for Machine Tools and Factory Management Pascalstraße 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin10587 Germany

The absorptivity of metallic materials plays an important role in high-power laser beam welding. It affects the amount of absorbed laser power leading to the heating and melting of the surfaces to be joined and is highly dependent on the temperature. Nonetheless, this key characteristic is often ignored in numerical simulations and an empirical parameter determined by trial-And-error approaches is rather implemented to calibrate the results. In the present work, the temperature dependence of laser absorption is included in a three-dimensional multiphase numerical model considering the coupled fluid flow and heat transfer. The calculated laser absorption is determined by the temperature-dependent material properties, laser characteristics, and incident angle of the laser beam. It is found that the temperature dependence of the laser absorption is crucial for accurately determining the keyhole and weld pool geometries, which is validated by experimental measurements using 304 austenitic steel. © 2024 The Authors.

关键词： Laser beam welding

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Process behaviour of segmented and actuated tool electrodes for variable shaping in sinking EDM 22

Process behaviour of segmented and actuated tool electrodes ...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Uhlmann, Eckart Thißen, Kai Westhoff, Bela Schulte Streckenbach, Jan Ludwig, Jonas Maas, Jürgen Technische Universität Berlin Institute for Machine Tools and Factuatory Management IWF Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany Technische Universität Berlin Mechatronic Systems Lab EMK Germany

ISBN: (纸本)9781998999118

In sinking electrical discharge machining (S-EDM), many applications such as the manufacturing of injection moulds require numerous tool electrodes due to tool wear compensation. The manufacturing of tool electrodes causes a high cost and time expenditure in the entire process chain. This paper aims for a novel approach to a segmentation of the tool electrode in order to shape it variably. The shaping is realized by actuation of single tool electrode segments (STES) using miniaturized linear actuators. In the future, the roughing process in S-EDM could be carried out by segmenting and variably shaping of the tool electrode. To investigate the process behaviour of a segmented tool electrode in S-EDM, different geometry configurations of the tool electrodes are compared. Experimental results show a similar material removal rate for the different tool electrode configurations. The relative linear wear of a segmented tool electrode is only 7.7 % of the relative linear wear of a monolithic tool electrode. In order to dynamically position the STES, a miniaturized electrical linear drive is developed and constructed. The outer diameter of the actuator must not exceed the edge length of an STES. In the machine tool an actuated STES is tested and the material removal rate and the relative linear wear for different Z-axis lifting motions are analysed. The material removal rate could be increased by 37 % applying actuated Z-axis lifting motions compared to the process without Z-axis lifting motion. In this context the relative linear wear increased slightly. The results of this paper are used for the further development of the system to enable more efficient process chains in the EDM process. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Linear actuators

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Integrated Consideration of Data Flows and Life Cycle Assessment in Vehicle Dismantling processes

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Procedia CIRP 2024年 122卷 1018-1023页

作者： Janine Mügge Anne Seegrün Lynn Faßbender Theresa Riedelsheimer Philip Staufenbiel Kai Lindow Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany LRP-Autorecycling Leipzig GmbH Priesterstraße 6 04509 Krostitz Germany

The pursuit of environmental sustainability and resource conservation has underscored the growing significance of the circular economy paradigm across industries. This transformation is particularly pertinent within the automotive industry, necessitating a profound restructuring of the value chain, with a specific focus on end-of-life considerations. Significant potential for circular economy arises from the thorough examination of end-of-life vehicles and processes, involving strategies such as component reuse, material recycling and primary resource reduction. Providing process-, product-, component-, and material-specific information at the end-of-life of automotive vehicles can improve decision-making regarding circular strategies. It also demands for new digital solutions. This paper addresses an integrated approach of data flow analysis and Life Cycle Assessment (LCA) to enable a comprehensive monitoring of the environmental impact of these processes. First, the use case of end-of-life dismantling processes is presented - including pyrotechnics neutralization, vehicle dehydration, disassembly of reuse components as well as vehicle compaction. Secondly, the data demand respective information and material flows is depicted. As a main result, the LCA data flow model specifically tailored to the end-of-life vehicle dismantling processes is described. This model serves as a fundamental basis for analyzing the environmental impact of end-of-life processes combined with the underlying data flow.

关键词： Circular Economy Sustainability Life Cycle Assessment Data Flow Decision Support

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design model for digital shadows to support reconfiguration decisions in manufacturing

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Procedia CIRP 2025年 132卷 153-158页

作者： Michael Riesener Eric Rebentisch Alexander Keuper Aileen Blondrath Philipp Weber Günther Schuh Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Aachen Germany Sociotechnical Systems Research Center Massachusetts Institute of Technology (MIT) Cambridge USA Fraunhofer Institute for Production Technology IPT Aachen Germany

Personalized production is the result of a paradigm shift in manufacturing driven by customers who are seeking increasingly individualized solutions. Consequently, product families with a high number of variants and short innovation cycles force companies to capture smaller windows of opportunity to stay competitive in a global market. Reconfigurable Manufacturing systems can address this trend by enabling the manufacturing system to be reconfigured in response to changing environmental conditions. However, deciding when to execute a reconfiguration and selecting a suitable manufacturing system configuration for the future is a complex task that requires profound knowledge of the manufacturing system and potential environmental influences. Thus, this paper proposes utilizing Digital Shadows to substantiate reconfiguration decisions with a networked information base. To process this information into an objective decision support, Time-expanded Decision Networks evaluate a sequence of future reconfiguration decisions with regard to economic and environmental target dimensions.

关键词： Reconfigurable manufacturing system Digital twin Digital shadow Digital manufacturing Manufacturing flexibility

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