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International Conference on Emerging Technologies and Factory Automation (ETFA)

作者： Michael Kuhl Paul-Michael Mickel Fraunhofer Institute of Machine Tools and Forming Technology Chemnitz Germany Volkswagen Sachsen GmbH Zwickau Germany

ISBN: (纸本)9781424427277

Laser welding has a whole series of benefits such as high welding velocity or minor heat yield which is why it is becoming increasingly important. Meeting strength and quality requirements for welding seams is of eminent significance in automobile design. Unfortunately, there might be problems due to the degassing gaps needed between the joining parts when using the galvanized sheet metal that is customary in car body design. This causes incomplete fusion to form with excessively large gap dimensions that cannot be identified from outside. Nor do process monitoring systems available on the market detect these faults with sufficient reliability. VW Sachsen GmbH and the fraunhofer institute for machine tools and forming technology studied the reasons for the inadequacies of conventional systems in the MAINE X joint research project. This article presents the findings and makes recommendations for sufficient methods of detection.

关键词： Laser fusion Welding Signal processing Fault detection Chemical lasers machine tools Gas lasers Coaxial components Condition monitoring Chemical technology

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Improving the precision by thermal simulation

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ATZproduktion worldwide 2009年第3期2卷 4-9页

作者： Neugebauer, Reimund Zwingenberger, Carsten Kehl, Gerhard Fraunhofer Institute for Machine tools and Forming technology IWU Chemnitz Germany Gebr. Heller Maschinen-fabrik GmbH in Nürtingen Germany

In the development of modern machine tools for the automotive industry, higher productivity, higher metal removal rates and lower machining tolerances are increasingly calling for allowance to be made for misalignments due to thermal factors. Improving the accuracy of thermal simulation was the subject of a project conducted at the fraunhofer institute for machine tools and forming technology (IWU).

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Application in milling of coated tools with rounded cutting edges after the film deposition (vol 58, pg 61, 2009)

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CIRP ANNALS-MANUFACTURING technology 2009年第2期58卷 722-722页

作者： Bouzakis, K. -D. Gerardis, S. Katirtzoglou, G. Makrimallakis, S. Bouzakis, A. Cremer, R. Fuss, H. -G. [a]Laboratory for Machine Tools and Manufacturing Engineering Mechanical Engineering Department Aristoteles University of Thessaloniki Thessaloniki Greece [b]Fraunhofer Project Center Coatings in Manufacturing in Centre for Research and Technology Hellas (CERTH) Thessaloniki Greece [c]Fraunhofer Institute for Production Technology (IPT) Aachen Germany [d]CemeCon AG Würselen Germany

Sharp cutting edges of coated tools are often rounded to increase their stability. In the described investigations coated cutting edges of cemented carbide inserts were variously rounded by grinding. The coating thickness distributions in the transient region between tool flank and rake were determined by an appropriate evaluation of ball cratering tests using confocal microscopy. The cutting performance of the tools was examined in milling at different cutting speeds and chip lengths, which were adjusted based on FEM calculations. The results demonstrated that even cutting edges with slightly revealed substrate can effectively withstand the cutting loads.

关键词： Coatings Cutting edge roundness Wear

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Applying modal analysis for comparing various FE models of human pelvic bone

Applying modal analysis for comparing various FE models of h...

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16th International Congress on Sound and Vibration 2009, ICSV 2009

作者： Werner, Michael Quickert, Martin Kunze, Holger Voigt, Christian Hoffmann, Falk Steinke, Hanno Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Str. 44 01187 Dresden Germany University of Leipzig Department of Orthopaedic Surgery Laboratory for Biomechanics Liebigstr. 20 04103 Leipzig Germany University of Leipzig Institute of Anatomy Liebigstraße 13 04103 Leipzig Germany

ISBN: (纸本)9781615677368

Finite element analysis (FEA) is a wide-spread method for studying the mechanical properties of structures. Finite element models (FE models) are being increasingly used in medical technology and biomechanics for calculating dynamic problems with bones and artificial limbs. X-ray computer tomography data is used to create models that supply very precise information on morphology and tissue density. This article describes how experimental measurements of the dynamic behavior of the human hip bone can be obtained to verify different FE modeling approaches. Several mapping functions known from the literature will be used for material parameters in the FE models and the findings are compared. This paper specially focuses on the measuring method streamlined for fresh preparations using a 3-D laser vibrometer for the first time to capture oscillations threedimensionally.

关键词： Bone

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Application of ant colony optimization to inspection planning

Application of ant colony optimization to inspection plannin...

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IEEE International Conference on Computational Intelligence for Measurement Systems and Applications (CIMSA)

作者： Robert Schmitt Hanqing Zheng Xiongfei Zhao Niels Konig Raphael Rocha Coelho Laboratory of Machine Tools and Production Engineering Rwth Aachen University Aachen Germany Fraunhofer Institute of Production Systems and Design Technology (IPK) Aachen Germany

Within this paper the application of an ant colony optimization (ACO) algorithm to inspection planning is presented. Since inspection planning is a time consuming task, optimizing these activities plays a major role in the quality inspection field. In this paper the extraction procedures of local inspection path planning (LIPP) and measurement device selection (MDS) to travelling salesman problem (TSP) and subset problem are presented respectively. An ACO algorithm based on Max-Min Ant System (MMAS) is presented for solving the problems. Experiment on industrial workpiece shows the applicability of ACO to inspection planning.

关键词： Ant colony optimization Inspection Path planning Production planning technology planning Continuous production Production systems Joining processes Cost function Artificial intelligence

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Investigations on the adjustment of the modelling section in 2D simulations of milling processes

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International Journal of Machining and Machinability of Materials 2009年第1-2期6卷 69-82页

作者： Uhlmann, E. Mattes, A. von der Schulenburg, M. Graf Gerstenberger, Robert Institute for Production Systems and Design Technology Fraunhofer Gesellschaft Pascalstr. 8-9 Berlin 10587 Germany Institute for Machine Tools and Factory Management Technische Universität Berlin Pascalstr. 8-9 Berlin 10587 Germany

Conducting 3D simulation of milling processes still causes high efforts. There, only small workpiece sections can be modelled so far, instead of the entire contact width. Approaches using 2D simulation pose an interesting alternative. Here, the two-dimensional perspective is gained by dividing the workpiece into different sections perpendicular to the feed rate. This, however, requires a modelling approach that covers arbitrary contact widths along with a high mesh density in the area of chip formation. Automatically adjusting the modelling section hereby helps to model contact width up to 180 by segmentally simulating the rotation of the milling cutter. This paper presents the investigations on the effect of the most important parameters which influence sufficiently accurate computation of the equivalent cutting forces as in conventional 2D simulation models using the software DEFORM 2D. Copyright © 2009, Inderscience Publishers.

关键词： Finite element method

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Modern methods of preforming titanium alloys for forging aero engine vanes

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VDI Berichte 2008年第2028期 253-260页

作者： Neugebauer, R. Lorenz, B. Steger, J. Holstein, D. Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Leistritz Turbinenkomponenten GmbH Remscheid Germany

ISBN: (纸本)9783180920283

Intermediate forming aimed at distributing the material volume contributes towards better utilization of the material, reducing the amount of energy necessary for heating and improving quality by near-net-shape geometries. A range of different forming operations exists for realizing material distribution. This paper gives an overview of the process technologies used for distributing the material in an intermediate forming stage in the closed die forging of aero engine vanes and also illustrates their application areas. The development of a single cross wedge rolling operation will save two upsetting operations and one extrusion operation. A considerable reduction in cycle times and in manufacturing costs is the result of the shortened process chain. Additionally, the number of ancillary processes, such as heating, adjustment and lubricant application are reduced as well.

关键词： Aircraft engines

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High precision laser structuring of micro forming tools 10

High precision laser structuring of micro forming tools

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10th Anniversary International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2008

作者： Schubert, A. Schneider, J. Edelmann, J. Burkhardt, T. Gross, S. Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (纸本)9780955308253

Because of the increasing demands for cost-effective and high-precision micro fluidic components the micro hot embossing technology becomes more and more important. An essential element of this technology is the required micro forming tool. At the moment the requirements for the minimum tool sizes are in a range of 100 um with accuracy below 2 um. However, the exactness demands partially can reach to the sub micrometer area [1]. The required structural sizes and structure forms as well as the used tool materials limit the application of conventional processes like milling. The structuring with laser offers an alternative method because the material removal with a laser beam allows the manufacturing of very fine structures also in hard and brittle materials. For initial experimental investigations a high strength ceramic material (silicon carbide) was used to produce forming tools for micro fluid components. It succeeded to produce structures with dimensions smaller than 20 um and in a depth of 200 um. The evaluation showed very good surface qualities (roughness below RZ 2.55 um) and a high geometrical accuracy. First replication experiments in PMMA (polymethyl methacrylate) and polycarbonate also show good results and comparable structure qualities.

关键词： Ceramic materials

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New approach for the characterisation of sheet materials - A precondition for the use of new sheet materials and forming processes

New approach for the characterisation of sheet materials - A...

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9th International Conference on technology of Plasticity, ICTP 2008

作者： Neugebauer, R. Sterzing, A. Müller, R. Silbermann, K. Fraunhofer Institute for Machine Tools and Forming Technology IWU Germany

ISBN: (纸本)9788957081525

The fraunhofer institute for machine tools and forming technology has set itself the challenge of characterising the material behaviour of very recently developed sheet metal materials. To this end, an integrated concept for the determination of material characteristics has been established. This consists in further developing well-known methods based on innovative characterisation concepts for describing phenomena such as springback, anistropy and the Bauschinger Effect. Using this approach, information relating to the interaction of sheet material, lubrication and forming tool can be derived.

关键词： Sheet metal

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Method for the compensation of process inherent form deviation in hot embossing of glass 10

Method for the compensation of process inherent form deviati...

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10th Anniversary International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2008

作者： Schubert, A. Edelmann, J. Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (纸本)9780955308253

During the hot pressing of glass (e.g. precision glass moulding, hot embossing) form deviations between the tool geometry and the manufactured glass formed part arise. Reasons for it are different thermal expansion behaviour of the materials and technological parameters. The form deviation resulting from these measured variables gains more and more significance with a rising scale of miniaturization. For the hot embossing of flat glass substrates with several cavities (e.g. micro lens arrays, microfluidic components) at the fraunhofer IWU a method was developed, in order to determine the total form deviation with the help of uncomplex shaped dies experimentally. The obtained accuracy is sufficient in order to correct ordinary optical geometries, like spherical cavities, or the pitch of V-grooves and channel structures respectively. For different tool materials and inorganic glasses according to this method correction factors were determined to compensate the process inherent form deviation. In this way complex iteration steps in the manufacturing of the tool moulds can be minimized.

关键词： Glass

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