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A Practical Approach to Realize a Closed Loop Energy Demand Optimization of Milling Machine Tools in Series production 18th

A Practical Approach to Realize a Closed Loop Energy Demand ...

引用

18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Can, Alperen Schulz, Hendrik El-Rahhal, Ali Thiele, Gregor Krüger, Jörg Daimlerstraße 143 Mercedes-Benz AG Berlin12277 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascal-Straße 8-9 Berlin10587 Germany

ISBN: (纸本)9783031288388

Energy efficiency is becoming increasingly important for industry. Many approaches for energy efficiency improvements lead to the purchase of new hardware, which could neglect the sustainability. Therefore, optimizing the energy demand of existing machine tools (MT) is a promising approach. Nowadays energy demand optimization of MT in series production is mainly done manually by the operators, based on implicit knowledge gained by experience. This involves manual checks to ensure that production targets like product quality or cycle time are met. With data analytics it is possible to check these production targets autonomously, which allows optimizing production systems data driven. This paper presents the approach and evaluation of a closed loop energy demand optimization of auxiliary units for milling MT during series production. The approach includes, inter alia, a concept for machine connectivity using edge devices and a concept for validating production targets. © 2023, The Author(s).

关键词： Energy efficiency

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Experimental and Numerical Investigation of the Forming Zone in Dieless Wire Drawing Process of Thin Biometallic Wires 14th

Experimental and Numerical Investigation of the Forming Zone...

引用

14th International Conference on technology of Plasticity, ICTP 2023

作者： Braatz, Merle Bohlen, Jan Ben Khalifa, Noomane Institute of Material and Process Design Helmholtz-Zentrum Hereon Geesthacht Germany Institute for Production Technology and Systems Leuphana Universität Lüneburg Lüneburg Germany

ISBN: (纸本)9783031410222

The influence of the dieless wire drawing process parameters on the forming zone of magnesium- and zinc-based wires are investigated. For this purpose, a numerical thermo-mechanical finite element model of the dieless wire drawing process is developed. For the validation of the numerical model and for experimental investigation of the forming zone, experiments are carried out using a flexible wire drawing setup with the same process parameters as for the numerical model for selected magnesium- and zinc-based alloys. The results show that reduction in cross-sectional area of up to 30% is possible for magnesium-based wires. Furthermore, a localization of the forming zone is essential for feasible parameter settings and high diameter reductions in one drawing pass. In addition, the length of the forming zone itself can be influenced not only by the material and the process temperature, but also by the process speeds. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Numerical models

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Influence of Process Parameters and Die design on the Microstructure and Texture Development of Direct Extruded Magnesium Flat Products 14th

Influence of Process Parameters and Die Design on the Micros...

引用

14th International Conference on technology of Plasticity, ICTP 2023

作者： Nienaber, Maria Safieh, Nabil Bohlen, Jan Ben Khalifa, Noomane Institute of Material and Process Design Helmholtz-Zentrum Hereon Geesthacht Germany Institute for Production Technology and Systems Leuphana Universität Lüneburg Lüneburg Germany

ISBN: (纸本)9783031410222

A parametric study was carried out on the direct extrusion of magnesium flat products made of AZ31 and ZN10, in which the extrusion speed and the die geometry were varied. This leads to a change in recrystallization behavior (process temperature), material flow and strain path. The resulted microstructure and texture development were investigated using EBSD measurements. Additionally, a finite element model for AZ31 was developed based on the parametric study and later used helping to understand the material flow and strain path during the extrusion. The obtained knowledge is essential to optimize the die geometry and process parameters and allows a more controlled development of microstructure and texture during extrusion of magnesium. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Magnesium

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Application of laser doppler vibrometry to characterize the laser drilling process 23

Application of laser doppler vibrometry to characterize the ...

引用

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

作者： Uhlmann, Eckart Hein, Christoph Schweitzer, Luiz Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany University Medicine Greifswald Department of Orthopedics and Orthopedic Surgery Germany

ISBN: (纸本)9781998999132

Laser drilling is being used more and more frequently in many industries, such as the aerospace, medical and electronics industries, to produce precision bores. A wide range of technically difficult-to-machine materials are applied. Laser drilling has already been intensively researched in order to investigate the basic mechanisms of the drilling process and the influences of various machining parameters on the quality of the holes. These findings have explicitly led to more successful machining processes of various technical components and industries. Despite all the advantages, there are some limitations of the laser drilling process and thereby a demand for innovative solutions to increase productivity. This paper presents a novel approach to the characterisation of the laser drilling process through the analysis of the acoustic signal characteristics. The objective is to apply a new generation of optical microphones to detect key aspects of the laser drilling process. This enables the development of new strategies to optimize the laser processing parameters, increasing repeatability and productivity for industrial applications. © 2023 Euspen Headquarters.

关键词： Optimization

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REPLICATION OF FUNCTIONAL SURFACES MICRO-STRUCTURED BY EDM 37

REPLICATION OF FUNCTIONAL SURFACES MICRO-STRUCTURED BY EDM

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37th Annual Meeting of the American Society for Precision Engineering, ASPE 2022

作者： Uhlmann, Eckart Polte, Mitchel Ludwig, Jonas Bolz, Robert 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)9781887706568

Functional surfaces are applied in a broad range of industries ranging from automotive over aerospace to medical technology. In this paper, the manufacturing of molds micro-structured by sinking electrical discharge machining (sEDM) and the surface replication on polycarbonat (PC) is discussed. The presented analysis shows the ability to replicate hydrophobic and hydrophilic effects on PC samples from micro-structured molds fabricated by sEDM. © 2022 Proceedings - ASPE 2022 Annual Meeting. All right reserved.

关键词： Molds

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Diamond slide burnishing for the finishing of electrical discharge machined surfaces 22

Diamond slide burnishing for the finishing of electrical dis...

引用

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

作者： Uhlmann, E. Polte, M. Yabroudi, S. Waiblinger, N. 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)9781998999118

Electrical discharge machining (EDM) represents a key manufacturing technology in a broad range of industries, e. g. aerospace, automotive and mould making. Current industrial and scientific relevant challenges are long machining times to achieve the surface roughness values needed, excessive tool electrode wear and the related huge number of tool electrodes needed. At state of the art, the challenges mentioned strongly limit the economic efficiency of precision EDM processes. To overcome these major challenges, the substitution of time consuming EDM polishing processes by diamond slide burnishing (DSB) shows great potential. During the process, a monocrystalline spherical diamond burnishing tool is moved along the surface of the workpiece with a defined process force. In this way the surface is specifically compressed and roughness peaks are smoothed. Within this work the applicability of diamond slide burnishing for the finishing of electrical discharge machined surfaces was investigated. For this purpose, three VDI grades with different surface roughness values were subsequently machined by DSB. The results show that the surfaces with different initial surface conditions can be successfully finished by DSB. The surface roughness of VDI grade 30 is identified as an upper limit for the surface preparation by EDM. A significant improvement of the surface roughness Ra by 93 % and a reduction of the processing time by 40 % could be achieved by the post-processing using DSB. Therefore, the new process chain presented shows great potential for being used in the field of tool and mould making and especially for the production of injection moulds. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Surface roughness

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DEM simulation of centrifugal disc finishing 22

DEM simulation of centrifugal disc finishing

引用

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

作者： Uhlmann, E. Polte, J. Kuche, Y. Landua, F. 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)9781998999118

The finishing of small components with complex geometries is a major industrial challenge. One process that is suitable for targeted post-processing is centrifugal disc finishing with wet and dry media. In this process, the workpieces float as bulk material together with the abrasive particles in a container and are completely surrounded by the abrasive medium. As shown in previous studies, the Discrete Element Method (DEM) is suitable for investigations of grinding processes with specified workpiece motions. To simulate unpredictable workpiece motion, a new approach is being tested in which the workpieces themselves are treated as particles. Within this research paper, results for the post-processing of centrifugal disc finishing with the software ROCKY DEM are presented. The investigation results show good correlation between the numerical determined pressures and the analysis results of the rounded workpiece edges on test components made of mould-steel X13NiMnCuAl4-2-1-1. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Grinding (machining)

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Framework of an experimental setup to enable an adaptive process control based on surrogate modelling 22

Framework of an experimental setup to enable an adaptive pro...

引用

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

作者： Uhlmann, E. Polte, J. Bösing, M. Schuler, N. 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)9781998999118

Numerical simulations can help to reduce the necessity of experimental studies. Nevertheless, these simulations are costly in terms of their computational effort resulting in significant expenditure of time and hence prevent a flexible adaption to continuously changing process conditions in real time. To address this shortcoming, the paper describes a framework for the application of surrogate models to enable an adaptive process control in real time. Following, an experimental setup to validate the general framework is designed for a laser metal deposition process. In particular, the component distortion shall be simulated and the results are then used to train the surrogate models. By measuring the final component distortion the quality of the surrogate models can be assessed. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Process control

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Investigation of additive manufactured tungsten carbide-cobalt tool electrodes for sinking EDM 37

Investigation of additive manufactured tungsten carbide-coba...

引用

37th Annual Meeting of the American Society for Precision Engineering, ASPE 2022

作者： Uhlmann, Eckart Polte, Mitchel Hörl, Robert Braun, Thomas Bolz, Robert 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)9781887706568

Increasing product complexity and continuous developments in related tool and mould making industry require ongoing advances in manufacturing processes like electrical discharge machining (EDM). To meet the increasing requirements, the development of adapted EDM processes and tool designs is necessary. Additive manufacturing (AM) enables the manufacturing of complex tool electrode geometries with interior flushing channels for EDM processes with very few restrictions regarding the design. This accounts even for tungsten carbide-cobalt (WC-Co), which is a suitable material for EDM tool electrodes with various advantages, e.g. thermal and mechanical stability. This paper shows first results of additive manufactured WC-Co tool electrodes for the use in sinking EDM and the related development process. © 2022 Proceedings - ASPE 2022 Annual Meeting. All right reserved.

关键词： Additives

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Zirconium dioxide-reinforced aluminium oxide ceramic for micro-milling of graphite 22

Zirconium dioxide-reinforced aluminium oxide ceramic for mic...

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

作者： Uhlmann, E. Polte, M. Polte, J. Hocke, T. Wendt, M. 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)9781998999118

Tool and mould making is one of the most important sectors for production of complex parts with highest economic efficiency. Particularly the milling process is a key technology for the manufacturing of tool electrodes for electrical discharge machining (EDM). Beside copper, graphite is the most industrial relevant tool electrode material for sinking-EDM. According to the state of the art the machining of graphite results in high tool wear in consequence of strong chemical and abrasive effects. Currently, uncoated and cost intensive diamond coated cemented carbide tools are used for industrial applications. High tool costs and short tool life have a negative impact on the economic efficiency of the manufacturing process and increase the overall production costs. To reduce the production costs, the needs for innovative cutting materials and dedicated manufacturing processes are high. The zirconium dioxide-reinforced aluminium oxide ceramic used in this investigation shows a great potential because of the high hardness H, the missing binder phase and the covalent bond. The aim of this investigation is the examination of the application behaviour of ceramic cutting tools during the machining process of graphite. Therefore, dedicated milling tests in partial and full cut were carried out. For evaluation of the application behaviour of the ceramic tools, the surface quality of the machined graphite depending on the wear of the tools was considered. The results show that a minimum surface roughness of Ra = 0.80 µm and average surface roughness of Rz = 6.55 µm could be achieved in first milling tests. Due to a strong sharpening effect of the cutting edge during the machining, the possibility was provided to produce complex components with highest precision and without chipping behaviour. The machining of graphite using ceramic milling tools shows extensive advantages compared to conventional milling tools, which may positively affect the economic efficiency of machining gr

关键词： Milling (machining)

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