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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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Two-colour thermography for measurement of temperature distribution in laser beam welding 13

Two-colour thermography for measurement of temperature distr...

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13th CIRP Conference on Photonic Technologies, LANE 2024

作者： Gumenyuk, A. Bakir, N. Rethmeier, M. Unter den Eichen 87 Berlin12205 Germany Technische Universität Berlin Pascalstrasse 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 Berlin10587 Germany

Solidification cracking is a frequently observed phenomenon in laser beam welding of austenitic stainless steels and other metallic alloys. Characterisation of cracking susceptibility requires knowledge of the precise and spatially resolved temperature distribution near the solidification front in the welding process. Thermography is a standard tool that provides a qualitative estimate of the 2D temperature field. The general disadvantage of this method is its dependence on the emission characteristics of the measured object. For welding applications, these can vary significantly in the temperature range above and below the melting temperature. For this purpose, we have developed a thermography-based measurement technique using a SWIR camera system in combination with two narrow bandpass filters that use the principle of two-wavelength pyrometry to estimate absolute temperature values. This technique was used to determine the temperature distributions and gradients near the solidification front of laser-welded austenitic steel. The results were validated by other measurements. © 2024 The Authors.

关键词： Laser beam welding

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Prediction of Quality in Thermographic Spray Spot Applications with Machine Learning Algorithms 56

Prediction of Quality in Thermographic Spray Spot Applicatio...

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56th CIRP International Conference on Manufacturing systems, CIRP CMS 2023

作者： Uhlmann, Eckart Polte, Julian Koutrakis, Nikolaos-Stefanos Pyka, Lasse Ider, Müslüm Thomas, Georg Rupprecht, Christian Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

Due to the high number of influences in production applications, quality fluctuation and deviating results in thermal spray applications are a challenging issue in manufacturing processes. This paper presents a concept for an adaptive process control based on different machine learning algorithms that are utilized to correlate input parameters with output results in thermal spray processes. For that purpose, a test environment was developed, incorporating different application scenarios with various input parameters. During the experiments, a series of measurements was performed, that is used to describe and evaluate the process. The extracted data of the conducted experiments are transformed into features and serve as the data input for the development of machine learning models based on various algorithms. These algorithms offer a prediction of the peak position, which describes the deviation of the programmed application spot, thus offering a quality prediction by utilizing solely the input process parameters. This work provides an approach based on the compared algorithms, that can be applied to create an adaptive process control, by adjusting the input parameters during the thermal spray application process. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://***/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the 56th CIRP International Conference on Manufacturing systems 2023.

关键词： Machine learning process control quality prediction thermal spray process

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Auto-encoder-based algorithm for the selection of key characteristics for products to reduce inspection efforts

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International Journal of Quality and Reliability Management 2023年第7期40卷 1597-1620页

作者： Greipel, Jonathan S. Frank, Regina M. Huber, Meike Steland, Ansgar Schmitt, Robert H. Department of Model-based Systems Chair of Production Metrology and Quality Management WZL | RWTH Aachen University Aachen Germany Institute of Statistics RWTH Aachen University Aachen Germany Fraunhofer Institute for Production Technology IPT Aachen Germany

Purpose: To ensure product quality within a manufacturing process, inspection processes are indispensable. One task of inspection planning is the selection of inspection characteristics. For optimization of costs and benefits, key characteristics can be defined by which the product quality can be checked with sufficient accuracy. The manual selection of key characteristics requires substantial planning effort and becomes uneconomic if many product variants prevail. This paper, therefore, aims to show a method for the efficient determination of key characteristics. design/methodology/approach: The authors present a novel Algorithm for the Selection of Key Characteristics (ASKC) based on an auto-encoder and a risk analysis. Given historical measurement data and tolerances, the algorithm clusters characteristics with redundant information and selects key characteristics based on a risk assessment. The authors compare ASKC with the algorithm Principal Feature Analysis (PFA) using artificial and historical measurement data. Findings: The authors find that ASKC delivers superior results than PFA. Findings show that the algorithms enable the cost-efficient selection of key characteristics while maintaining the informative value of the inspection concerning the quality. Originality/value: This paper fills an identified gap for simplified inspection planning with the method for the efficient selection of key features via ASKC. © 2022, Emerald Publishing Limited.

关键词： Feature selection Inspection planning Key characteristics Machine learning Simulation

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Experimental Investigations of the Mechanical-technological Properties and Fatigue Strength of Stainless Steel Bolting Assemblies 34th

Experimental Investigations of the Mechanical-technological ...

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34th International Ocean and Polar Engineering Conference, ISOPE 2024

作者： Glienke, Ralf Hagemann, Melanie Hanebeck, Robin Schwerdt, Daniela Denkert, Christian Wegener, Fritz Dörre, Maik University of Applied Science Technology Business and Design Wismar Germany Fraunhofer-Institute for Large Structures in Production Engineering IGP Rostock Germany University of Cooperative Education Staatliche Studienakademie Riesa Germany

ISBN: (纸本)9781880653784

Due to their corrosion resistance, bolting assemblies manufactured from stainless steel are becoming more and more important in various applications, such as in offshore structures and machinery. An enhanced level of knowledge based on publications of the last few years offers opportunities of using preloaded bolting assemblies. However, missing design rules and insufficient data basis on the fatigue strength of stainless steel bolting assemblies limit their application. Neither Eurocode 3 for structural engineering nor VDI 2230-1 for mechanical engineering provide sufficient design rules regarding the verification of the fatigue strength of stainless steel bolts. A total of 286 fatigue tests at constant amplitude loading (CAL) up to 107 load cycles were carried out on bolting assemblies made from austenitic, duplex stainless steel and carbon steel in nominal sizesM6 to M20 with strength grades 80 and 100 (8.8/10.9), which are presented in this paper. © 2024 by the International Society of Offshore and Polar Engineers (ISOPE).

关键词： Corrosion resistance

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Targeted Data Generation in the Continuous production of Anode Slurries for Lithium-Ion Battery Cells 6

Targeted Data Generation in the Continuous Production of Ano...

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6th International Conference on Artificial Intelligence in Information and Communication, ICAIIC 2024

作者： Oberdiek, Sven Jalowy, Leah Vazquez, Flavio Gonzalez Risling, Monika Wahl, Katja Quality and Reliability Management Fraunhofer Institute for Manufacturing Engineering and Automation IPA Stuttgart Germany Dispersing Technology Fraunhofer Institute for Manufacturing Engineering and Automation IPA Stuttgart Germany Purity-specific Automation Systems Fraunhofer Institute for Manufacturing Engineering and Automation IPA Stuttgart Stuttgart Germany Data and Application Services for Digital Production Fraunhofer Institute for Manufacturing Engineering and Automation IPA Stuttgart Germany

ISBN: (纸本)9798350344349

This research paper explores the transition from batch mixing to continuous mixing processes for the production of slurries used in lithium-ion battery cells. The conventional batch mixing methods, prevalent in European industry, suffer from time-consuming cleaning processes, lengthy mixing times, and the inability to monitor paste conditions in real-Time. The study proposes a solution using continuous mixing with a twin-screw extruder, highlighting advantages such as reduced cleaning time, immediate sample characterization, and minimized production risks. The research aims to develop a test setup and procedure to accelerate the understanding of the continuous mixing process, leveraging minimal resources and time, and facilitating the training of artificial intelligence algorithms. The ultimate goal is to create a digital twin encompassing all influencing factors for predictive and prescriptive analytics. The methodology involves literature reviews, expert surveys, and experimental setups, with an emphasis on inline measuring devices. The paper presents results related to relevant product characteristics, influencing factors, and the selection of suitable measuring equipment. The experimental setup includes a database structure, human-machine interface, and visualization of measurement data. The study concludes with insights into the correlation analysis of influencing factors and product characteristics, emphasizing the need for further experiments and the development of algorithms for predictive quality assessments in continuous mixing processes. © 2024 IEEE.

关键词： Lithium-ion batteries

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Experimental Investigations of the Preload-time-behaviour of Lockstud systems Enhanced by Finite Element Analysis 34th

Experimental Investigations of the Preload-time-behaviour of...

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34th International Ocean and Polar Engineering Conference, ISOPE 2024

作者： Hagemann, Melanie Schwarz, Mathias Schröder, Markus Blunk, Christoph Glienke, Ralf Schwerdt, Daniela Henkel, Knuth-Michael University of Applied Sciences Technology Business and Design Wismar Germany Fraunhofer-Institute for Large Structures in Production Engineering IGP Rostock Germany Howmet Fastening Systems-Industrial Fastener Division Telford United Kingdom University of Rostock Faculty of Mechanical Engineering and Marine Technology Chair of Joining Technology Rostock Germany

ISBN: (纸本)9781880653784

This article presents current results on the initial preload of Lockstud systems of nominal sizes M12 to M20, property class 8.8 and 10.9 in uncoated black, zinc flake coated and hot-dip galvanised conditions during the assembly process. In addition, it provides design recommendations for the preload as given in accordance with Technical Bulletin DVS/EFB 3435-2. Comprehensive numerical investigations of Lockstud systems have shown validated simulations of the assembly process, including the resulting preload (2D model), the stress concentrations with critical failure locations (3D model) and additionally the slip load of a slip-resistant connection (3D model). © 2024 by the International Society of Offshore and Polar Engineers (ISOPE).

关键词： Finite element method

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Post-Processing of Additive Manufactured Medical Metal Parts 11

Post-Processing of Additive Manufactured Medical Metal Parts

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11th ASPE-euspen Summer Topical Meeting on Advancing Precision in Additive Manufacturing

作者： Uhlmann, Eckart Polte, Julian Hocke, Toni Al-Sanhani, Ghamdan Lahoda, Christian Institute for Production Systems and Design Technology IPK Technische Universität Berlin Berlin Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Berlin Germany

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F5G OpenLab: Enabling Twin Transition through Ubiquitous Fiber Connectivity

F5G OpenLab: Enabling Twin Transition through Ubiquitous Fib...

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International Conference on Transparent Optical Networks

作者： Mihail Balanici Behnam Shariati Pooyan Safari Paul Chojecki Moritz Chemnitz David Przewozny Johannes Karl Fischer Ronald Freund Fraunhofer Institute for Telecommunications Heinrich-Hertz-Institut Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

The paper introduces a new open laboratory, the F5G OpenLab, which aims at fostering the advancement of fiber-based solutions for everything. F5G OpenLab intends to aid in creating a sustainable and eco-friendly ICT industry and accelerate the digital transformation through autonomous networking solutions that are secure and trustworthy. In particular, the purpose of the F5G OpenLab is to establish an ecosystem for the validation of optical networking solutions that facilitate twin transition, provide a vendor-neutral platform for the assessment of vertical use cases, and enable the development of fiber-based solutions. It provides a platform to verify and unify next-gen networking solutions, access to early hardware and software releases, and unique testing and measurement facilities. Finally, the F5G OpenLab supports the development of blueprints for a green and digital transformation, capitalizing on the benefits of fiber technology for all industry sectors. We present its architecture as well as key features and capabilities. Moreover, we report several proof-of-concept demonstrations focused on industry 4.0 vertical use-cases.

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