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INVESTIGATION ON REDUCTION OF TOOL WEAR IN ELECTRICAL DISCHARGE FINISHING PROCESSES WITH GRAPHITE TOOL ELECTRODES 39

INVESTIGATION ON REDUCTION OF TOOL WEAR IN ELECTRICAL DISCHA...

引用

39th Annual Meeting of the American Society for Precision Engineering, ASPE 2024

作者： Uhlmann, Eckart Polte, Mitchel Lezama, Sergio Thißen, Kai Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

ISBN: (纸本)9781887706612

In order to meet the increasing demand for products with complex geometries, the investigation of the use of novel materials for Electrical Discharge Machining (EDM) processes is necessary. In the case of Sinking Electrical Discharge Machine (S-EDM) it has been proven that the use of graphite tool electrodes enables a high material removal rate while maintaining a low relative tool wear in roughing operations. However for finishing operations, copper is still the most used material due to its lower relative tool wear. Nevertheless, the manufacturing of graphite tool electrodes with complex geometries is more cost-effective in comparison with copper tool electrodes. This makes graphite a suitable alternative material for EDM finishing operations, if the parameters used ensure a low relative tool wear whilist achieving the desired surface roughness in adequate machining times. © 2024 Proceedings - ASPE 2024 Annual Meeting. All rights reserved.

关键词： Graphite electrodes

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Mm-Wave Connectivity in Industrial Environments: A Measurement Study at 28 and 60 GHz

Mm-Wave Connectivity in Industrial Environments: A Measureme...

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2024 IEEE Global Communications Conference, GLOBECOM 2024

作者： Schott, Aron Ichkov, Aleksandar Beckmann, Niklas König, Niels Simic, Ljiljana Rwth Aachen University Institute for Networked Systems Germany Fraunhofer Institute for Production Technology Aachen Germany

ISBN: (纸本)9798350351255

The spectrum-rich millimeter-wave (mm-wave) bands and exploiting multi-antenna technologies are envisioned as a key enabler for future high speed communication networks. 5G-NR in automation and industry requires supporting not only eMBB but also URLLC applications to meet the demands in production processes. Providing high-rate mm-wave coverage in real-world industrial environments is challenging and necessitates detailed and site-specific characterization of the directional link opportunities and beam management requirements for network planning of mm-wave factory deployments. In this paper, we present the results of our large-scale mm-wave measurement study using phased antenna arrays in a machine production hall. We systematically collect received signal strength data over fine-grained 3D TX/RX orientations for 31 spatially-dense RX positions in three typical factory scenarios in the 28 GHz and 60 GHz bands. We study the impact of transmitter placement and operating frequency band on the achievable data rate and the beam management effort considering the data rate demands of next-generation industrial networks. Our results show that the 28 GHz band provides sufficient connectivity to deliver data rates of up to 1 Gbps without the need for sophisticated beam management, which is in strong contrast to outdoor mobile mm-wave applications where active beam tracking is crucial to provide seamless connectivity. © 2024 IEEE.

关键词： Antenna phased arrays

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Simulation of ultrasonic-assisted grinding for improved efficiency in hard-to-machine materials: A direct approach to analyze material removal mechanisms 20

Simulation of ultrasonic-assisted grinding for improved effi...

引用

20th CIRP Conference on Modeling of Machining Operations in Mons, CIRP CMMO 2025

作者： Uhlmann, Eckart Gülzow, Bernhard Zhang, Xinyu Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

The application of ultrasonic superposition is utilized in industrial manufacturing to enhance the chip formation mechanisms, particularly when machining hard-to-machine materials. The institute for Machine Tools and Factory Management (IWF) systematically investigates the interactions between tool and workpiece during ultrasonic-assisted grinding of high-performance ceramics. To gain an in-depth understanding of the microscopic engagement conditions, these conditions are analyzed by simulation. For this purpose, a Python simulation tool based on a geometrical-kinematic modeling approach was developed to analyze the ultrasonic-assisted circumferential longitudinal grinding process. It was demonstrated that ultrasonic assistance leads to smaller and more uniform chip thicknesses which reduce grinding forces and minimizes tool wear. Also, it promotes brittle chip formation mechanisms and improves the efficiency of the grinding process compared to conventional machining. For further investigation, the simulation model was adapted to the transverse face grinding process. In this context, not only the circumferential surface but also the face surface of the grinding tool is engaged with the workpiece. Additionally, the penetration of the workpiece is no longer tangential with the rotational movement but perpendicular to the tool movement. Analogous to the results of the analysis of the circumferential longitudinal grinding process, the influences of ultrasonic excitation on the engagement conditions, particularly the resulting chip thickness and surface topography for the adapted process kinematics were determined and are presented in this paper. © 2025 The Author(s).

关键词： Grinding (machining)

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Determination of critical local straining conditions for solidification cracking at laser beam welding by experimental and numerical methods

Determination of critical local straining conditions for sol...

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94th Annual Meeting of the International Association of Applied Mathematics and Mechanics, GAMM 2024

作者： Bakir, Nasim Gumenyuk, Andrey Rethmeier, Michael Berlin Germany Technische Universität Berlin Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany

The phenomenon of solidification cracking has been the subject of numerous research projects over the years. Great efforts have been made to understand the fundamentals of hot cracking. It is generally agreed that solidification cracks form in the solidification range between the liquidus and solidus temperatures under the combination of thermal, metallurgical and mechanical factors. There is still a need to determine the time-resolved strain distribution in the crack-sensitive region in order to analyse the local critical conditions for solidification cracking phenomena. This was a strong motivation for the development of a measurement system used in this study to estimate the local strains and strain rates in the zone where the solidification crack is expected to occur. The laser beam welding experiments were conducted using the Controlled-Tensile-Weldability test (CTW test) to apply an external strain condition during welding to generate solidification cracks. The CTW test is a test method for investigating the susceptibility of laser-welded joints to solidification cracking, in which the sample can be subjected to a defined strain at a defined strain rate during welding. In combination with experimental investigations, numerical simulations provide spatially detailed and time-dependent information about the strain development during the welding process, especially regarding the critical conditions for solidification cracking. Therefore, this tool was also used in the present study to evaluate the accuracy of measurement methods and to estimate experimentally derived values and their concrete influence on the formation of solidification cracks. By integrating experimental methods and numerical simulations, this study investigates the spatially resolved and temporally changing development of strain during welding, with a particular focus on the critical conditions that lead to the formation of solidification cracks. The use of numerical simulations serves a dual p

关键词： Laser beam welding

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Automated manufacturing of drug-coated balloons for coronary artery disease 23

Automated manufacturing of drug-coated balloons for coronary...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Hein, C. Schlüter, S. Wang, Y. Dürre, G. Fraunhofer Institute for Production systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technical University Berlin Germany

ISBN: (纸本)9781998999132

Drug-coated balloons were established as an improvement for coronary angioplasty in recent years. However, due to the balloons' high manufacturing variance, coating them evenly is challenging. Therefore, production is still carried out at least partially manually. Within the framework of the presented research project, a four-axis machine kinematics has been developed, enabling even coating of balloon catheters of various sizes in a controlled climate. High-precision measurement using a confocal sensor allows for compensation for the manufacturing variance of the balloon catheter by means of surface mapping. The average coating thickness as well as its distribution can be determined similarly. Thus, in case of insufficient coating, local reapplication can be carried out. With the developed machine system, it is therefore possible to produce coating area densities in the range of 4 μg mm-2 -2 with minimal inhomogeneities. © 2023 Euspen Headquarters.

关键词： Coatings

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Characterisation and investigation of ion-implanted boron-doped single crystal diamonds as temperature sensor for ultra-precision machining 23

Characterisation and investigation of ion-implanted boron-do...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Polte, M. Hocke, T. Thißen, K. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9781998999132

Ultra-precision machining is a crucial manufacturing process for the production of optical components in automotive, medical and aerospace industry and enables high dimensional accuracies and low surface roughness values. Dedicated single crystal diamond tools enable the manufacturing of optical and functional surfaces such as mirrors or lenses. Despite the high mechanical hardness, temperature induced chemical wear of the diamond tools occures during the process. To characterise und interpret the wear behaviour of diamond tools, the cutting temperature needs to be analysed. At state of the art, there are no precise methods available for analysing temperatures in the cutting zone of a single crystal diamond tool in order to identify the wear behaviour online during the process. Therefore, a dedicated measurement system based on boron-doped CVD single crystal diamonds as temperature sensor was developed. The electrosensory features of the fully boron-doped diamonds enable a direct temperature measurement in the cutting zone. To enable high sensitive temperature measurements, ion-implantation was used for partial and specific boron-doping close to the cutting edge of single crystal diamonds. To fundamentally evaluate the quality of the doping and contacting structures as well as the general process of the ion-implantation three different doping structures were investigated using single crystal diamond blanks prior doping the cutting tools. For this purpose, the boron-doped structures were optically characterised and the correlations between the resistances and the temperatures were evaluated as a function of different doping-levels and doping-lengths. First results show the successful application of the ion-implantation for boron-doping of single crystal diamonds. It could be proven that the selected boron-levels as well as boron-lengths lead to different initial conditions of the analysed specimens. Dedicated ionimplantation of single crystal diamond tools represents

关键词： Surface roughness

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Wear mechanism of single crystal diamonds in ultra-precision cutting of graphite for air bearing applications 23

Wear mechanism of single crystal diamonds in ultra-precision...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Polte, M. Hocke, T. Felder, F. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany

ISBN: (纸本)9781998999132

In order to meet the continuously increasing function-determining requirements of complex precision components, advances in machine tool components are necessary in addition to technological developments. In this context, motorized spindles in particular show great potential for enabling further increases in accuracy. To achieve high stiffness and damping behaviour of spindle systems, aerostatic bearings made of graphite with bearing gaps Sg S ≤ 1 μm are necessary. Regarding the state of the art, uncoated tungsten carbide tools, diamond coated carbide tools and thick film chemical vapour deposition (CVD) diamonds are used for cutting graphite materials. Cutting with these tools leads to asymmetric breakout behaviour of the graphite grains as well as high tool wear during machining, resulting in insufficient shape accuracies and surface qualities. A promising approach to overcome the current challenges for aerostatic bearing components made of graphite is the use of single crystal diamonds (SCD) with characteristic low rounded cutting edge radii rß ≤ 20 nm as well as cutting-edge waviness wa ≤ 200 nm. Besides the material-specific properties of the SCD, tool wear occurs during the cutting of graphite. For this purpose, the abrasive wear mechanism and surface attrition of SCD were analysed concerning specific blasting tests with defined time intervals of 60 s ≤ tb ≤ 3,000 s and different process conditions. Furthermore, two types of graphite granulate with grain sizes in a range of 200 μm ≤ gs ≤ 400 μm were used. First results show a dimensional loss of material on the investigated specimens made of SCD depending on the process conditions, whereby an influence of the surface attrition could be proven. © 2023 Euspen Headquarters.

关键词： Graphite

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DEM simulation of centrifugal disc finishing using smoothed particle hydrodynamics 23

DEM simulation of centrifugal disc finishing using smoothed ...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Polte, J. Kuche, Y. Hocke, T. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9781998999132

Centrifugal disc finishing is a widely used technology forserial post-processing of small components made of various materials. During the process, the workpieces are completely surrounded by dry or moist abrasive media, making it difficult to obtain precise information about particle contacts or the movement of the workpieces. Numerical analysis through the discrete element method (DEM) has the potential to improve the understanding of the process, but the accurate representation of moist particles with varying contact conditions remains a challenge. This paper compares different contact models using the ROCKY DEM software, including the liquid-bridge model and the smoothed particle hydrodynamics (SPH) model. The analysis indicates that, compared to other models, SPH demonstrates clear advantages in representing process water flow and is better suited for cases with higher water content in the medium. © 2023 Euspen Headquarters.

关键词： Finite difference method

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Implementation of a handling system for using carbon fibres as tool electrodes in micro-ED drilling 23

Implementation of a handling system for using carbon fibres ...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Polte, M. Yabroudi, S. Lezama, S. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany

ISBN: (纸本)9781998999132

Electrical discharge machining (EDM) processes represent an established process for the machining of complex geometries in hard to cut and electrically conductive materials. Nevertheless, micro-electrical discharge drilling still poses the challenge of machining holes with diameters dh ≤ 50 μm. The preparation of even smaller pin tool electrodes demands a great amount of non-productive time, which often involves the use of additional electrical discharge dressing processes for its manufacturing. A possible solution is the use of single carbon fibres with diameters 5 μm ≤ del ≤ 10 μm as tool electrodes. The use of these single fibres comprises a challenge due to their geometrical and mechanical properties, e.g. diameter and brittleness. To overcome this challenge, an existing handling system for carbon fibres was re-designed considering the obstacles that arose with the use of previous versions of such systems. This includes the replacement of the liquid rubber coating of the movable clamping jaw in order to use foam rubber to achieve a better distribution of the clamping force that establishes the electrical contact between the carbon fibre and a conducting copper plate. The geometry of the borosilicate glass micro-pipette was redesigned to ensure an accurate positioning of the carbon fibre due to its inner tip diameter 15 μm ≤ dt ≤ 35 μm and to enable the use of fibre electrodes with a length of 15 mm ≤ le ≤ 25 mm. This hinders the deflection of the fibre tip during the machining process and enables the precise guidance of the fibre. Furthermore, the developed handling system was implemented for performing single discharge experiments, in which parameters such as open circuit voltage, charge current and discharge capacity were varied in order to determine their influence on the material removal process. © 2023 Euspen Headquarters.

关键词： Rubber

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Increasing the Relative Density of Additively Manufactured Tungsten Carbide-Cobalt Tool Electrodes for EDM 38

Increasing the Relative Density of Additively Manufactured T...

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38th Annual Meeting of the American Society for Precision Engineering, ASPE 2023

作者： Uhlmann, Eckart Polte, Mitchel Hörl, Robert Reimann, Robert Braun, Thomas Hocke, Toni Technische Universität Berlin Institute for Machine Tools and Factory Management Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

ISBN: (纸本)9781887706599

The investigation of novel materials for the use of tool electrodes for electrical discharge machining (EDM) is necessary to meet the increasing demands for complex products to be machined. Continuous product developments require improvements in manufacturing processes such as Sinking Electrical Discharge Machining (S-EDM). To meet these requirements, the development of customized EDM-processes and innovative tool designs is essential. Additive Manufacturing (AM) enables the production of sophisticated tool electrode geometries. This includes internal flushing channels for EDM-processes with minimal design constraints. Laser Powder Bed Fusion (LPBF) is a suitable method for this purpose. The presented paper shows an investigation to further increase the relative density ρrel of additively manufactured S-EDM tool electrodes using tungsten carbide-cobalt (WC-Co) as material for tool electrodes. © 2023 Proceedings - ASPE 2023 Annual Meeting. All rights reserved.

关键词： Electrodes

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