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14th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2020

作者： Süße, Marian Putz, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Planning and optimization of facility layouts have been investigated for decades and manifold approaches are applied for structuring and design of production layouts. However, results heavily depend on the experience and creativity of involved planning experts. Currently, complexity of planning processes constantly increases, e.g. due to further requirements of energy and media supply. Generative Design, hitherto mainly applied in component development, provides opportunities to cope with a much larger solution space and develop creative layout concepts. Thus, based on a structured overview on established planning methods, a concept and first results of factory layout planning with Generative Design are described. © 2021 The Authors. Published by Elsevier B.V.

关键词： Plant layout

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A New Paradigm in Surface Reconstruction: LTP Features from Surface Images for Inverse Process Modeling

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Procedia CIRP 2025年 134卷 975-980页

作者： Mei Yun Liu Thomas Wiener Martin Dix Professorship Production Systems and Processes Chemnitz University of Technology Straße der Nationen 62 09111 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

This study explores the adaptation of Local Ternary Patterns (LTP) for surface reconstruction, extending its use beyond traditional texture analysis. A systematic methodology, including patch optimization, parameter optimization, and feature selection, is proposed to extract surface-relevant features from images. Applied to spark-eroded surfaces, LTP enables differentiation of surface structures, with slightly reduced classification performance for surfaces with very fine or very coarse roughness. Despite this, the method demonstrates high potential for inverse process modeling, offering a cost-effective alternative for correlating manufacturing parameters with surface characteristics, contributing to improved process optimization and quality control in precision manufacturing.

关键词： Inverse Process Model Local Ternary Patterns (LTP) Surface Reconstruction Electrical discharge machining (EDM)

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Incremental micro-forming for surface finishing with piezoelectrically actuated hammering tool with coupling unit 21

Incremental micro-forming for surface finishing with piezoel...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Fiedler, Maik Kolouch, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9780995775190

machine hammer peening can be referred as an incremental mechanical surface treatment procedure, which can be realized by using various tools being based on various actuator principles. For the purpose of high productivity, a high-performance drive for generating vibrations in the tool of a high frequency is desired. Therefore, this paper presents a new hammer peening tool with a piezoelectric actuator. In order to facilitate this actuator principle for practical applications, a coupling unit is necessary being installed between the tool and the machine. This coupling unit insulates the process vibration at the machine (e.g. a machine tool or an industrial robot) and changes the operating mode of the hammer peening process from position controlled to force controlled. In such way, the accuracy of the positioning movement as well as the accuracy of the workpiece are not the issue anymore and the piezoelectrically actuated tool with a low stroke of 120 µm can be deployed for practical applications. This tool together with the coupling unit can reach hammering frequencies in the range from 800 to 1300 Hz. These frequencies enable higher feed rates and productivity of the hammer peening process than tools with pneumatic or electromagnetic actuators being available on the market. For the purpose of demonstration of the tool potential, some experimental tests are presented in this paper. Here, workpiece being milled like in die making were treated by the hammer peening process with the new tool. The surface were smoothed from Ra 1.18 μm to Ra 0.10 μm. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Piezoelectric actuators

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Numerical Investigation of Full Forward Extrusion with Downstream Strain Hardening via Deep Rolling 14th

Numerical Investigation of Full Forward Extrusion with Downs...

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14th International Conference on technology of Plasticity, ICTP 2023

作者： Herrmann, P. Müller, M. Weiser, I.F. Herrig, Tim Bergs, Thomas Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen University Campus-Boulevard 30 Aachen52074 Germany Fraunhofer Institute for Production Technology Steinbachstraße 17 Aachen52074 Germany

ISBN: (纸本)9783031410222

Due to the process-specific high material utilization and the associated high energy and resource efficiency, cold forming processes represent an important technology in the processing of steel. To increase wear resistance and fatigue strength, cold formed workpieces are often case hardened. However, case hardening is an energy- and cost-intensive process step. As a complement, the finishing may be realized by means of mechanical surface treatments, like deep rolling, machine hammer peening or shot peening. These treatments improve the surface layer condition of the component by inducing favorable residual compressive stresses, strain hardening, grain refinement and surface smoothing to increase wear resistance and fatigue strength. For the design of the surface treatment process of an impact extruded component, there is a considerable deficit in scientific knowledge about the concrete cause-effect relations between process parameters and surface integrity as well as component performance. To make these interactions explainable, knowledge about internal stress and temperature distributions during process execution is necessary. These can only be determined numerically. For this reason, the finite element method is a suitable tool for an overall investigation of the processes. In the present work, a manufacturing process consisting of full forward extrusion and deep rolling is implemented as finite element model. The focus of this model is a fully coupled thermal-stress analysis. The investigations are carried out for the material 16MnCr5. This case-hardening steel is used to produce workpieces via cold forming, which are used in both hardened and unhardened condition. The experimental performance of the simulations performed here has already been carried out for this material. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Finite element method

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Acoustic process monitoring for ultrasonic-assisted deep drilling 27

Acoustic process monitoring for ultrasonic-assisted deep dri...

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27th International Congress on Sound and Vibration, ICSV 2021

作者： Georgi, Oliver Rüger, Carlo Rentzsch, Hendrik Hochmuth, Carsten Putz, Matthias Dix, Martin Papsdorf, Gunther Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany SINUS Messtechnik GmbH Leipzig Germany

ISBN: (纸本)9788378807995

Regarding deep drilling, problems in terms of chip formation and removal, burrs, tool vibrations as well as process reliability occur. Modern scientific approaches face these problems and aim to improve productivity, quality and reliability to reduce manufacturing costs. At the same time, there is a trend to use in-process monitoring and control in terms of adaptive machining processes in order to operate cutting processes close to the limits of stability. The application of ultrasonic assistance for drilling and deep drilling processes enables multiple advantages like reduced tool wear and burr formation as well as enhanced chip breaking behaviour. Moreover, ultrasound enables the use of previously unused physical effects to obtain information from the process zone and identify process conditions. In this context, the paper presents an approach of using modulation phenomena to evaluate dynamic process stability, using ultrasound as a carrier signal for low-frequency vibrations related to the deep drilling tool. In addition, the resonant coupling of ultrasonic system and cutting operation is used to draw direct conclusions about the load behaviour of the machining process from characteristics of the resonant vibration system. This directly leads to the possibility to perform in-process monitoring of tool wear. The article covers the theoretical basics, the hardware realization as well as experimental investigations regarding acoustic process monitoring for ultrasonic-assisted deep drilling. © "Advances in Acoustics, Noise and Vibration - 2021" Proceedings of the 27th International Congress on Sound and Vibration, ICSV 2021. All rights reserved.

关键词： Process monitoring

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Numerical Modeling of the Redistribution of Residual Stresses in Deep Rolled Cross Bores in Shafts from GJS700-2 14th

Numerical Modeling of the Redistribution of Residual Stre...

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14th International Conference on technology of Plasticity, ICTP 2023

作者： Uhlmann, Lars Reissner, Felix Rathnakar, Shashaank Nambla Herrig, Tim Baumgartner, Jörg Bergs, Thomas Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 Aachen52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstrasse 17 Aachen52074 Germany Fraunhofer Institute for Structural Durability and System Reliability LBF Darmstadt Germany

ISBN: (纸本)9783031410222

Lightweight design efforts are generally limited by highly stressed areas. In the case of shafts with cross bore the cross bore forms a notch. Due to geometry and position, those notches lead under cyclic torsional loading to stress peaks in the component, which appear as highly stressed areas. In order to counteract tensile stress peaks, compressive residual stresses may be induced into the surface layer by means of surface treatments such as deep rolling. The induction of compressive residual stresses may delay crack initiation and growth. When deep rolled components are subsequently subjected to cyclic loading, the induced residual stresses are redistributed until a stable residual stress state is established, which is decisive in the assessment of the fatigue strength. The influence of deep rolling on the surface properties of cross bores in shafts made of GJS700 and the redistribution behavior of the induced residual stresses under subsequent cyclic torsional loading is mostly unknown. The objective of this work was therefore to identify the cause-effect relationships between the deep rolling parameters (pressure, overlap) as well as the cyclic loading and the resulting surface properties. Therefore, experimental investigations of deep rolling and of the subsequent cyclic torsional loading were carried out. Subsequently, the process sequence was modeled numerically consisting of a deep rolling and a torsion model. The experimental tests were used to validate the models. Finally, the cause-effect relationships between the deep rolling parameters on the residual stresses and the redistribution due to cyclic torsional loading were investigated. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Residual stresses

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Effects of ultrasonic vibration on the silver deposition in powder mixed EDM for antibacterial surface modification 23

Effects of ultrasonic vibration on the silver deposition in ...

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

作者： Bui, Viet D. Berger, Thomas Martin, André Harnisch, Karsten Döring, Joachim Bertrand, Jessica Schubert, Andreas Chemnitz University of Technology Institute for Machine Tools and Production Processes Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Otto-von-Guericke University Magdeburg Institute of Materials and Joining Technology Universitätsplatz 2 Magdeburg39106 Germany Otto-von-Guericke University Magdeburg Department of Orthopaedic Surgery Leipziger Str. 44 Magdeburg39120 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9781998999132

Previous studies have demonstrated that silver nano-powder mixed electrical discharge machining (PMEDM) is a potential technique for concurrent ablative shaping medical implants and generating antibacterial layers on the surfaces. PMEDM modified surfaces with deposited silver offer excellent antibacterial properties along with very good biocompatibility. However, for medical applications, PMEDM is still facing challenges providing sufficiently uniform distribution of deposited silver and preventing spattered layers that might lead to delamination from the modified surface. It was indicated that ultrasonic vibration (UV) has remarkable effects on the fluid dynamics in the spark gap, which positively affect the silver distribution and reduce the generation of spattered layers. Consequently, in this study, a Ti6Al4V workpiece is vibrated with an ultrasonic frequency of 22.3 kHz and an amplitude of 2.5 μm during the PMEDM process. The effect of vibration direction in X and Z axis on the silver deposition is evaluated while discharge energy is varied up to 125 μJ. For comparative analyses also PMEDM without vibration assistance is investigated. Ti6Al4V hollow tool electrodes with an outer diameter of 3 mm and an inner diameter of 2.5 mm are utilised for internal flushing with a pressure of 4 bar. A hydrocarbon-based dielectric fluid is mixed with silver nanopowder at a concentration of 15 g/l. Results show that UV assisted PMEDM increases the content of deposited silver up to 1.7 times compared to PMEDM without vibration. UV with vibration in Z direction and pulse energies of 55 μJ and 125 μJ results in uniform silver distribution and significantly decreases spattered layer formation, whereas the use of vibration in X-direction leads to negative effects. By carefully selecting machining conditions such as vibration direction and amplitude, wall thickness of hollow tool electrode and powder concentration, PMEDM provides surfaces with promising characteristics for medical

关键词： Medical applications

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UV-Imprint of micro-textured polymer films for biomedical disposables 22

UV-Imprint of micro-textured polymer films for biomedical di...

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

作者： Gärtner, Eric Edelmann, Jan Hackl, Claudia Roussak, Liudmila Tomasova, Lea Guttenberg, Zeno Gnüchtel, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Leipzig Germany SensLab GmbH Leipzig Germany Ibidi GmbH Gräfelfing Germany WESKO GmbH Stollberg Germany

ISBN: (纸本)9781998999118

In the life science sector, increasing demands on the reproducibility and accuracy of lab-on-chip systems require new manufacturing technologies for the production of polymer films with multifunctional surfaces. A mass-production capable and cost-effective way to pattern microfluidic films is the manufacturing process of UV injection molding. Therefore, the aim of the project is to develop microstructured polymer films with multifunctional surface properties by means of an injection molding UV plate-to-plate (P2P) replication process. For this purpose, a special film injection molding system was developed that allows filling with different formulations, curing by UV light and molding of the required microstructures. In respect to the application of the microstructured polyacrylate films in cell-based assays as well as biosensor disposables, microstructures of various geometries were designed and produced in the P2P process. In addition, cell tests were performed in this study in order to evaluate the biocompatibility and optical quality of the substrates, and to verify the functionality of the microstructures. Here, we show that the structured polyacrylate foil is a suitable substrate that can be implemented in plastic microfluidic chips for cell-based assays and biosensor disposables. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Polymer films

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New metals remanufacturing business models in automotive industry 15

New metals remanufacturing business models in automotive ind...

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15th CIRP Conference on Intelligent Computation in Manufacturing Engineering, ICME 2021

作者： Copani, Giacomo Shafinejad, Parnia Hipke, Thomas Haase, Rico Paizs, Tibor Via A. Corti 12 Milano20133 Italy Fraunhofer-Institute for Machine Tools and Forming Technologies Reichenhainer Straße 88 Chemnitz09126 Germany

Metals represent about the 60-70% of vehicles weight. At the End of Life, after the disassembly of dangerous and some re-usable and recyclable parts, metals are scrapped and melted, with significant energy consumption. Innovative cold-reforming and joining technologies, coupled with systems to retrieve material information, can allow a second life before melting through remanufacturing. This would open the way to new circular business models in automotive providing added-value to customers as well as new market opportunities for OEMs. This paper investigates the potential of these approaches, as the results of the European H2020 "CarE-Service"project. © 2022 The Author(s).

关键词： Metals

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EXTENDED STUDY ON THE COMPOSITION OF MAGNETORHEOLOGICAL FLUIDS FOR THE POST-PROCESSING OF MICRO-MILLING tools 39

EXTENDED STUDY ON THE COMPOSITION OF MAGNETORHEOLOGICAL FLUI...

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

作者： Sordon, Fabian Lahoda, Christian Polte, Mitchel Uhlmann, Eckart Maas, Jürgen Mechatronic Systems Lab EMK Technische Universität Berlin Germany 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)9781887706612

Cutting edge preparation is a critical step in the fabrication of micro-milling tools, helping to remove grain chipping and to reduce tool wear. In our previous research, we explored the use of magnetorheological fluids for directed immersed tumbling under magnetic excitation, demonstrating its potential through significant and precise material removal rates and reduced processing times. This study expands on that work by examining how the composition of the abrasive magnetorheological fluid affects surface quality and the long-term performance of the fluid. Various compositions of magnetorheological fluid samples were tested on high-speed steel specimens using a custom-designed test bench, which enables the variation of the magnetic field. The microgeometry of the cutting edges, including the maximum chipping, was recorded before and after processing. Results indicate that compositions yielding larger abrasive particles, combined with high magnetic and abrasive particle volume fractions lead to improvements in surface quality and material removal rate. © 2024 Proceedings - ASPE 2024 Annual Meeting. All rights reserved.

关键词： Magnetorheological fluids

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