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14th International Conference on technology of Plasticity, ICTP 2023

作者： Graf, Marcel Pippig, Robert Lehnert, Tim Jedynak, Angelika Härtel, Sebastian CMMC GmbH Saxony Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technologies IWU Saxony Chemnitz Germany Brandenburg University of Technology Cottbus-Senftenberg Cottbus Germany

ISBN: (纸本)9783031410222

The development of new materials or material systems is always accompanied by the development of processing technologies suitable for the material. The reduction of process steps, the saving of material and the optimization of material properties are aims of forming processes. The basis for this is the comprehensive characterisation of the thermos-physical and thermos-mechanical technologically relevant material behaviour, taking into account the real process conditions. In the present work, the material-specific process limits were determined by means of experimental simulation and used in the numerical simulation in order, on the one hand, to identify the forming steps for optimizing the manufacturing conditions and, on the other hand, to be able to set the final material properties. It was essential to homogenize the casting microstructure for the forming processes and to adjust it to globulitical grains by solution annealing. The previously limited forming behaviour of the cast AlSi9Mg alloy with 20 vol.-% SiC could be increased thus to forging-relevant plastic strains without occurring damages. Based on the comprehensive temperature-dependent material data, a one-step and resource-efficient manufacturing process for AMC materials by hot forming could be developed with the help of the FE software Simufact forming and validated in reality under near-industrial conditions. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Corrosion resistance

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Innovative actuating process for machining CFRP with force-controlled radial feed movement 33

Innovative actuating process for machining CFRP with force-c...

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33rd CIRP Design Conference

作者： Peter, Marie Sauer, Konstantin Regel, Joachim Dix, Martin Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

The use of lightweight materials such as carbon fibre reinforced plastics (CFRP) is increasing due to the demand for rising resource and energy efficiency, especially in the aerospace and automotive industries. Because of the high delamination tendency of these materials and their abrasive impact on the tool, the challenges in machining CFRP lie primarily in the drilling process and thus in the design of the drilling tool. In this paper, an innovative design of a drilling tool for machining CFRP with force-controlled radial feed movement of the cutting edges is presented. The aim of this tool is to create a tool axial force free process that uses a force-controlled radial feed motion, which matches the chip cross-section to the wear condition of the cutting edge. The tool concept is explained based on the functionality of the actuating process. Tests were evaluated with regard to process forces and drilling quality to show that the tool is capable of producing delamination-free bores in a tool axial force free 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)

关键词： Carbon fiber reinforced plastics

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An analysis of biomechanical requirements and actuating technologies of biomimetic hand exoskeletons regarding to driving force and stroke

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Procedia CIRP 2024年 125卷 24-29页

作者： Alina Carabello Kenny Pagel Welf-Guntram Drossel Professorship Adaptronics and Lightweight Design University of Technology Chemnitz Fraunhofer Institute for Machine Tools and Forming Technology IWU

Exoskeletons have gained importance recently. In the case of musculoskeletal diseases, they can restore or support the mobility of injured body parts; in everyday life, they can relieve the musculoskeletal system and thus contributes to the preservation of health into old age. However, active systems face challenges due to the efficient and reliable actuators. In the following, the example of the hand will be used to investigate what influence the individuality of the hand under consideration has on the selection of a suitable actuator about force and stroke. The literature outlines that tendon-driven mechanism with a biomimetic design are a promising approach for hand exoskeletons: The finger is actively moved by an actuator using artificial tendons positioned along the finger to match anatomical structures. For this purpose, actuators based on electromagnetic or pneumatic principles, and smart materials are described. The requirements for force and stroke of the drive can be derived from the analysis of finger kinematics. In this study the finger kinematics of 13 subjects were analyzed. The results show a scatter in stroke and force depending on the finger considered. To select a suitable actuator for the biomimetic hand exoskeleton, these results are compared with the force and stroke characteristics of various actuating principles. The comparison reveals that the choice of the actuator depends on the intended primary support for the hand (movement, endurance, grip strength). Hence, it can be deduced that step drivers meet the force and stroke requirements and may be a suitable alternative.

关键词： exoskeleton tendon-driven step driver actuator hand injury finger movement

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Development of a material selection decision support system for an automotive application

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Discover Mechanical Engineering 2024年第1期3卷 1-21页

作者： Chirinda, Gibson P. Matope, Stephen Nagel, Matthias University of Stellenbosch Private Bag X1 Matieland Stellenbosch 7602 South Africa Fraunhofer Institute of Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

This study presents the development of a material selection decision support system for an automotive rooftop tent. The system uses five parameters of material cost, formability, corrosion resistance, tensile strength and hardness to optimize material choice from a list of aluminium alloy options. This was done before production via the deep drawing process can commence. The parameters were quantified using the average market prices for each alloy, product requirements obtained from the case study and the performance data that was obtained from the uniaxial tensile and hardness tests. These inputs were combined with the developed material selection framework and then programmed into a web-based decision support system for automated, data-driven material selection. The output presents the recommendation for the optimum material that balances cost-effectiveness and performance. The decision support system was successfully used to select the optimum alloy for the rooftop tent. Results show that AA1050 is the optimum material, providing weight reduction at the minimum achievable cost without compromising the product requirements for the rooftop tent. The decision support system is also scalable, and this allows it to be used with larger datasets for different products and processes in the future. © The Author(s) 2024.

关键词： Aluminium alloy Automotive industry Decision support system Deep drawing Lightweighting Material selection

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Investigation of Surface Characteristics in Magnetic Field assisted Electrical Discharge Machining 7

Investigation of Surface Characteristics in Magnetic Field a...

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7th CIRP Conference on Surface Integrity, CSI 2024

作者： Bui, Viet D. Martin, André Berger, Thomas Schubert, Andreas Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

Electrical discharge machining (EDM) has demonstrated its promising potential for surface modification. The integration of materials from tool electrode or powder that is mixed into the dielectric fluid has proven to modify the workpiece surface to enhance its mechanical properties, realize antibacterial effects, or increase biocompatibility. Recent EDM studies showed that due to non-contact forces, properties of the modified surface such as roughness values and the thickness of modified layer were significantly influenced when using magnetic field assisted EDM. Consequently, in this study, an external magnetic field with a strength of 0.66 T is used to assist the material transfer from tool electrode to workpiece surfaces during the EDM process. Pure silver and copper tools with a diameter of 2 mm are used to modify surfaces of Ti6Al4V workpieces at a discharge energy of 125 µJ with different polarities. Results show that the assistance by magnetic field significantly increases the content of transferred material from tool electrode to the workpiece surface. Additionally, it increases material removal rate and reduces the modified layer thickness. Magnetic field assisted EDM is a potential technology for improving the efficacy of the EDM surface modification. © 2024 The Authors. Published by Elsevier B.V.

关键词： Titanium alloys

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Antibacterial Surface Protection using Electrical Discharge Machining with Zinc Tool Electrode for Medical Devices 6

Antibacterial Surface Protection using Electrical Discharge ...

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6th CIRP Conference on BioManufacturing, BioM 2024

作者： Bui, Viet D. Martin, André Berger, Thomas Steinert, Philipp Schubert, Andreas Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

Electrical discharge machining (EDM), widely used to fabricate medical devices, is applicable for antibacterial surface protection. Silver, transferred from tool electrode or powder suspended in the dielectric to the modified layer during the EDM process, significantly enhanced antibacterial properties of the modified surface. However, bacterial resistance to silver, which was widespread in clinical, still posed challenges for the modified surfaces containing silver. Zinc, owing to its strong antibacterial effects and no challenge related to Zn-resistant bacteria hitherto reported in clinical, was therefore used as tool electrode material to modify Ti6Al4V surfaces during the EDM process. Discharge energies up to 170 ìJ with different polarities were applied in the EDM milling process using deionized water-based dielectric fluid. Results show that discharge energy and polarity play a vital role in chemical composition and roughness of the modified surfaces as well as material removal rate and tool wear rate. The surfaces containing zinc contents up to 28 % can be generated. The use of a low energy generates zinc-rich surfaces with less micro-cracks. The EDM process using zinc tool electrode shows a promising potential for antibacterial surface modification of medical devices. © 2024 The Authors.

关键词： Deionized water

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Experimental setup for evaluation of electrical face contacts for high-current applications

Experimental setup for evaluation of electrical face contact...

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Production Technologies and Systems for E-Mobility (EPTS), International Conference on

作者： Sebastian Wieland Tingyan Sun Lars Kanzenbach Jörg Schneider Jan Edelmann Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (数字)9798350386172

ISBN: (纸本)9798350386189

The transmission of high electrical power via separable contact connections is a key challenge in the context of the energy transition. A well-known example is the charging interface of electric vehicles. To counteract the presently long charging time of battery systems, an innovative fast charging system using a face contact instead of classic plug-in contacts is being developed. To enable charging power in the megawatt range, an electrical contact surface is functionalized in such a way that, on the one hand, the contact resistance is reduced and, on the other hand, the thermal as well as the mechanical properties are improved. In addition to the simulation-based design of the contact surfaces and the development of manufacturing technologies, the required measurement and testing technology is a fundamental challenge. In this article the experimental setup for the long-term test of the electrical face contacts is being introduced. Using the test bench, electrical contacts can be automatically evaluated with regard to their temperature development and contact resistance at normal forces of up to 500 N with a current load of up to 600 A DC under constant or cyclic conditions. In this context the test procedure as well as first results of the thermo-mechanical properties of a face contact setup are being discussed.

关键词： Temperature measurement Temperature Surface resistance Thermal resistance Thermomechanical processes Surface charging Contact resistance

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Method for Evaluating and Identifying Energy-Efficient Process Chains for the Manufacturing of Press Hardening tools Based on the Deming Circle 18th

Method for Evaluating and Identifying Energy-Efficient Proce...

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18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Rautenstrauch, Anja Markov, Larisa Kräusel, Verena Faculty of Mechanical Engineering Institute for Machine Tools and Production Processes Professorship for Forming and Joining Technische Universitaet Chemnitz Reichenhainer Str.70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany

ISBN: (纸本)9783031288388

In response to rising energy demand, climate change and resource scarcity, the German government has set guiding targets for the transformation of energy systems by 2050. One goal is to increase energy efficiency in order to halve the demand for energy. An important instrument for increasing energy efficiency and reducing energy costs is the energy audit. By determining how much energy is consumed in which areas of the company, it is possible to identify where there is potential for savings. This paper presents an evaluation method for identifying energy-efficient process chains for the production of press hardening tools. The evaluation method is based on the Deming Circle and is intended to serve as a supporting tool for the energy audit. The method enables the analysis and evaluation of energetic variables of a process chain and is designed for manufacturing companies. © 2023, The Author(s).

关键词： Energy utilization

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Intuitive Robot Programming and Intelligent tools

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IST International Surface technology 2023年第2期16卷 8-9页

作者： Bdiwi, Mohamad Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Chemnitz Germany

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AI-driven force torque control strategies for further automate flexible high-precision, contact-intensive assemblies 57

AI-driven force torque control strategies for further automa...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Gu, Yunqi Otto, Ruth Maria Naumann, Martin Gjakova, Leutrim Löser, Rico Dix, Martin University of Applied Sciences Munich Lothstr. 34 Munich80335 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz09126 Germany Chemnitz University of Technology Chemnitz09111 Germany

Robotic assembly processes are integral to industrial manufacturing, traditionally relying on pre-programmed sequences that exhibit limited adaptability to uncertain conditions. Recent advancements propose AI-enhanced vision systems as viable solutions to mitigate uncertainty in automated tasks. Despite the potential of vision, contact-intensive, high-precision assembly processes need customized force-torque feedback strategies to perform the task. Parametrization for setup and adaption of force-torque processes are time consuming, but decisive for quality. This work outlines an AI-driven force-torque control strategic solution for peg-in-hole assembly task, which employs object detection algorithm to grasp the workpiece and determine flexible assembly position, with force-torque-informed DNN algorithm for error correction in terms of position, and digital twin to monitor the process and collect virtual data. © 2024 The Authors.

关键词： Robotic assembly

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