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Experimental investigations of the workpiece-media-interaction and the surface topography formation in centrifugal disc finishing

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Procedia CIRP 2022年 115卷 24-29页

作者： Marco Kopp Eckart Uhlmann Christian Kneider Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany

In this study the workpiece-media-interaction in centrifugal disc finishing is investigated using a miniaturised free movable force measuring system. Characteristics of the workpiece-media-interaction are derived and correlated with the surface topography formation of Ti-6Al-4V workpieces. As a result, it was found that characteristics of the workpiece-media-interaction such as the contact force between the media and the workpiece, the contact duration and the contact frequency are dependent on the type of media as well as the rotational speed of the disc. Consequently, both, the type of media as well as the rotational speed of the disc have an influence on the resulting surface roughness.

关键词： centrifugal disc finishing contact forces topography formation

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Residual stress assessment during cutting tool lifetime of CVD-diamond coated indexable inserts

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Procedia CIRP 2022年 108卷 799-804页

作者： E. Uhlmann D. Hinzmann Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany

Insufficient coating adhesion limits reproducibility regarding tool lifetime as well as workpiece quality during the application of CVD-diamond coated cutting tools. Depending on the combination of tungsten carbide substrate material, coating thickness as well as coating morphology, individual residual stress conditions exist within CVD-diamond coated cutting tool specifications. The application of these tools is accompanied by coating delamination as primary cutting tool failure. The tool lifetime of the respective cutting tool composition depends on the corresponding residual stress condition until crack development within the CVD-diamond coating initiates tool failure. During external cylindrical turning of hypereutectic aluminium silicon alloy AlSi17Cu4Mg-T6 the residual stress condition of a CVD-diamond coated cutting tool is assessed along the cutting edge, the rake face as well as flank face throughout the respective tool lifetime. Consequently, the progression of the residual stress condition until cutting tool failure regarding coating delamination is observed. During the tool lifetime of the investigated CVD-diamond cutting tools, compressive residual stress ∆σ R,c shifts to tensile residual stress ∆σ R , t underneath the cutting edge corner. The approximated residual stress difference of ∆σ R ≈ 5 GPa indicates stress peak relaxation processes, such as crack initiation, within the CVD-diamond coating.

关键词： diamond tool residual stress aluminum turning

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Influence of superimposed low frequency oscillations on single-pass honing of long-chipping steel

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Procedia CIRP 2022年 108卷 607-612页

作者： E. Uhlmann A. Rozek Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Pascalstraße 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany

Single-pass honing is used as a finishing process to meet high demands regarding form and dimensional accuracy of drilled bores. The disadvantages of single-pass honing compared to the conventional long-stroke honing are high process forces and torques as well as an increased risk of chip space clogging of the abrasive stones. A significant reduction in process forces and torques can be achieved by superimposing the axial movement with oscillations. In this work the kinematic basics of different oscillation parameters and their effects on single-pass honing of long-chipping steel are analyzed. It can be concluded that by superimposing low frequency oscillations in single-pass honing, the process forces and torques as well as the specific energy consumption can be reduced significantly without a decline in surface quality and form accuracy.

关键词： Surface Finish Honing Oscillation

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Sustainability transformation challenges for manufacturing companies and their employees: An approach how a serious game prepares and fosters the transformation

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AIP Conference Proceedings 2024年第1期3109卷

作者： Jens Mathis Rieckmann Patrick Gering Jan Torka Fraunhofer Institute for Production Systems and Design Technology (IPK) Division Corporate Management Berlin Germany

Besides the transformation process challenge towards intelligent networked production systems, the growing demand for the topic sustainability, which is integrated with the production process, creates an additional complex challenge for manufacturing companies. The industrial transformation process with regard to the focus of the fourth industrial revolution is enlarged in terms of the inquiry of sustainability and especially the circular economy. In particular, external political, economic and environmental factors, but at the same time society changes towards a sustainable mindset of people shape the future development. This article focuses on the question of how to sensitize and qualify employees of manufacturing companies with a serious game to start the preparation of the upcoming challenges regarding sustainable transformation. Starting from an optimized holistic production system as a start setting, currently discussed topics will be added as scenarios to teach and build up abilities to be prepared and face upcoming challenges.

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Influence of the weld pool geometry on solidification cracking in partial penetration high power laser beam welding

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Procedia CIRP 2022年 111卷 397-400页

作者： Nasim Bakir Ömer Üstündag Andrey Gumenyuk Michael Rethmeier Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 10587 Berlin Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 10587 Berlin Germany

Solidification cracking is still a serious problem in laser beam welding, especially in the welding of thick-walled plates. The influence of weld pool geometry on solidification cracking in partial penetration welding of thick plates is investigated within scope of this study. Therefore, a specific experimental setup of steel and quartz glass in butt configuration and on the side with high-speed camera were used to record the weld pool shape. In addition, the influence of laser inclination angle on the weld pool geometry and on solidification crack formation was investigated. The results show a bulge in the weld pool root, which is separated from an upper region by a necking region. This leads to a case where there are three different longitudinal region lengths with different solidification zones. This temporal sequence of solidification strongly promotes the formation of solidification cracks in the weld root.

关键词： Laser beam welding (LBW) solidification cracking partial penetration weld pool shape

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Inductive Sintering Module for Improved Multi-Die Attach in the Field of Power Packaging

Inductive Sintering Module for Improved Multi-Die Attach in ...

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IEEE CPMT Symposium Japan

作者： Christian Hofmann Patrick Rochala Martin Kroll Sushant Panhale Mario Baum Harald Kuhn Kiyoshi Oi Masaki Sanada Kei Murayama Department System Packaging Fraunhofer Institute for Electronic Nano Systems ENAS Chemnitz Germany Professorship for Forming and Joining Institute for Machine Tools and Production Processes (IWP) Chemnitz University of Technology Chemnitz Germany Department Systems Engineering Fraunhofer Institute for Electronic Nano Systems ENAS Chemnitz Germany Fraunhofer Institute for Electronic Nano Systems ENAS Chemnitz Germany Process Development Dept. SHINKO ELECTRIC INDUSTRIES CO. LTD. Nagano Japan

This work presents a heating technology for multi-die attach based on inductive silver sintering. Thus, the heat for the sintering reaction is confined locally to the bond region, avoiding heating of the entire power ...

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Digital Technologies Enabling Resilience in Manufacturing Networks 19th

Digital Technologies Enabling Resilience in Manufacturing Ne...

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19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Koutrakis, Nikolaos-Stefanos Magnanini, Maria Chiara Uhlmann, Eckart Polte, Julian Pei, Eujin Psarommatis, Foivos Brintrup, Alexandra Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Department of Mechanical Engineering Politecnico di Milano Via La Masa 1 Milano20156 Italy Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany Brunel University London Kingston Lane UxbridgeUB8 3PH United Kingdom University of Oslo Gaustadalleen 23B Oslo0373 Norway Department of Engineering Institute for Manufacturing University of Cambridge CambridgeCB3 0FS United Kingdom

ISBN: (纸本)9783031774287

Unforeseen events have the potential to cause disruptions throughout the entire manufacturing value chain, ranging from interruptions in production processes on the shop floor level to shutdowns in the supply chain and logistics. These disruptions increase the necessity for the establishment of manufacturing networks that prioritize cooperation and circularity to strengthen resilience, predict and counteract such impacts. This paper provides an overview of the main digital technologies required to create a resilient and sustainable manufacturing network and the implementation of the Manufacturing as a Service (MaaS) approach. For each digital technology, a synthetic characterization is provided, with respect to requirements, exemplary applications and involved standards. Challenges on the use of such technologies are presented and suggestions for future developments on the integration and deployment of digital technologies with the aim of achieving resilience in manufacturing networks is described. © The Author(s) 2025.

关键词： Smart manufacturing

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Application of tool electrodes oxidised with humid and dry air during the electro-discharge drilling of MAR-M247 alloy 21

Application of tool electrodes oxidised with humid and dry a...

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

作者： Uhlmann, E. Polte, M. Streckenbach, J. Camin, B. Chocholaty, O. Dinh, N.C. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany Institute for Materials Science and Technology Metallic Materials Technische Universität Berlin Germany Faculty of Mechanical Engineering Department of Material Science and Technology University of West Bohemia Czech Republic

ISBN: (纸本)9780995775190

The requirements and challenges of machining advanced materials in the field of aerospace, automotive and tool industry are increasing constantly. Due to their mechanical properties, cutting of high-strength materials such as superalloys is severely limited. Electro-discharge drilling can be used for the manufacturing of holes in hard to machine materials. Although electrical discharge machining (EDM) is successfully applied to the machining of holes in turbine blades, a lack of performance and challenges concerning the geometrical accuracy still remain. By applying inner flushing, the resulting electrically conductive debris is flushed through the lateral working gap, increasing the probability of arcs and short circuits. The resulting increased tool wear, conicity of the hole, limited hole depth and process instabilities are still challenging in electro-discharge drilling. In order to decrease the effects of the arcs and short circuits, a surface modification is applied to increase the electrical resistance of the lateral surface of the tool electrode. As a result, the mentioned impairments occur less frequently due to decreased occurrence of arcs and short circuits in the lateral working gap. For the present investigation copper tool electrodes were thermally oxidised in dry and humid air with different durations and used afterwards for electro-discharge drilling of MAR-M247. The tests were carried out on the machine tool AGIETRON Compact 1 from the company GF AgieCharmilles, Losone, Switzerland. Holes with a depth of t = 11 mm were drilled using various surface-modified tool electrodes with a diameter of d = 2 mm. Oxidation with dry air and a extended oxidation time resulted in a 18 % lower erosion duration, accompanied by an increase of the linear wear of the tool electrode Δle below 10 %. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Oxidation

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Introducing readiness scales for effective reuse of open source hardware

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Procedia CIRP 2022年 109卷 635-640页

作者： Robert Mies Martin Häuer Mehera Hassan Technische Universität Berlin Institute for Machine Tools and Factory Management PTZ 3 Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Digital engineering Pascalstr. 8-9 10587 Berlin Germany

Open source hardware (OSH) describes physical products that allow for "anyone to study, modify, produce, and distribute them". While OSH principles aim to support design reuse, recent studies have challenged whether this is properly applied in practice. Therefore, this article delivers an assessment scheme that allows to identify the readiness of OSH designs for reuse. Testing the scheme on OSH ventilator designs collected by the Publnv ventilator project showed overall good usefulness of the scheme and emphasised the need of unambiguous assessment scales based on common standards. Less than two thirds of Publnv’s listed projects fulfilled minimum criteria for openness.

关键词： open innovation open source hardware open source product development technology readiness documentation readiness design reuse

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MotorFactory: A Blender Add-on for Large Dataset Generation of Small Electric Motors

arXiv

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arXiv 2023年

作者： Wu, Chengzhi Zhou, Kanran Kaiser, Jan-Philipp Mitschke, Norbert Klein, Jan-Felix Pfrommer, Julius Beyerer, Jürgen Lanza, Gisela Heizmann, Michael Furmans, Kai Institute for Anthropomatics and Robotics Karlsruhe Institute of Technology Kaiserstraße 12 Karlsruhe76131 Germany wbk Institute of Production Science Karlsruhe Institute of Technology Kaiserstraße 12 Karlsruhe76131 Germany Institute of Industrial Information Technology Karlsruhe Institute of Technology Hertzstraße 16 Karlsruhe76187 Germany Institute for Material Handling and Logistics Karlsruhe Institute of Technology Kaiserstraße 12 Karlsruhe76131 Germany Fraunhofer Institute of Optronics System Technologies and Image Exploitation IOSB Fraunhoferstraße 1 Karlsruhe76131 Germany

To enable automatic disassembly of different product types with uncertain condition and degree of wear in remanufacturing, agile production systems that can adapt dynamically to changing requirements are needed. Machine learning algorithms can be employed due to their generalization capabilities of learning from various types and variants of products. However, in reality, datasets with a diversity of samples that can be used to train models are difficult to obtain in the initial period. This may cause bad performances when the system tries to adapt to new unseen input data in the future. In order to generate large datasets for different learning purposes, in our project, we present a Blender add-on named MotorFactory to generate customized mesh models of various motor instances. MotorFactory allows to create mesh models which, complemented with additional add-ons, can be further used to create synthetic RGB images, depth images, normal images, segmentation ground truth masks and 3D point cloud datasets with point-wise semantic labels. The created synthetic datasets may be used for various tasks including motor type classification, object detection for decentralized material transfer tasks, part segmentation for disassembly and handling tasks, or even reinforcement learning-based robotics control or view-planning. Copyright © 2023, The Authors. All rights reserved.

关键词： Large dataset

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