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International Conference on Control, Decision and Information Technologies (CoDIT)

作者： Gregor Thiele Theresa Johanni David Sommer Martin Eigel Jö rg Krü ger Department for Process Automation and Robotics Fraunhofer IPK Institute for Production Systems and Design Technology Berlin Germany Weierstrass Institute for Applied Analysis and Stochastics Berlin Germany Department for Industrial Automation at the Institute for Machine Tools and Factory Management Technical University of Berlin Germany

The manufacturing sector has witnessed a rapid rise in the importance of energy-efficient operation. For finding optimal set-points for industrial facilities, optimization problems of increasing complexity occur. Key challenges are the leak of derivative information and the curse of dimensionality. For systematic reduction of the search-space by decomposition of the model, a methodology for the inclusion of topology knowledge in the optimization procedure is developed. An implementation of OptTopo (Optimization based on Topology), embedded in a testbed, demonstrates its advantages compared to popular out-of-the-box-optimization. OptTopo could be integrated in energy management software offering advanced set-point control for complex facilities.

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SyProLei-A systematic product development process to exploit lightweight potentials while considering costs and CO2 emissions 32

SyProLei-A systematic product development process to exploit...

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32nd CIRP design Conference, CIRP design 2022

作者： Kaspar, Jerome König, Kristian Scholz, Johannes Quirin, Steven Kleiner, Sven Fleischer, Jürgen Herrmann, Hans-Georg Vielhaber, Michael Em Engineering Methods Ag Rheinstr. 97 Darmstadt64295 Germany Institute Of Engineering Design Saarland University Campus E2 9 Saarbrücken66123 Germany Wbk Institute Of Production Science Karlsuhe Institute Of Technology Kaiserstraße 12 Karlsruhe76131 Germany Lightweight Systems Saarland University Campus E3 1 Saarbrücken66123 Germany Fraunhofer Institute For Nondestructive Testing Izfp Campus E3 1 Saarbrücken66123 Germany

In lightweight design, developers are used to face the conflicting objectives of functional fulfillment, economic performance, and sustainability. Against this background, however, a clearly structured approach for the satisfied use of specific lightweight engineering methods within the product development is still missing. Thus, this contribution deals with the fundamental conception and first implementation of a systematic development methodology covering the disciplines of mechanics, electrics/electronics and software just like the focus on an integrated view on product, production and material aspects. To ensure an application-specific manifestation of the product development process for three exemplary use cases from small and medium-sized enterprises but also large corporations in the area of prosthetics, bike construction and plant engineering, the individually developed methods and tools are first generalized in order to make them adaptable to a wide variety of industries. As a result, one lightweight-specific method or tool (e.g., function mass analysis, "PPM solution correlator"or "2D layout & weight drafting") is introduced in more detail for all stages of the technically extended RFL(T)P approach derived from model-based systems engineering (MBSE). © 2022 The Authors.

关键词： Product development

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Modeling of the wet immersed tumbling process with the Discrete Element Method (DEM) 18

Modeling of the wet immersed tumbling process with the Discr...

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18th CIRP Conference on Modeling of Machining Operations, CMMO 2021

作者： Uhlmann, E. Fürstenau, J.-P. Kuche, Y. Yabroudi, S. Polte, J. Polte, M. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany CADFEM GmbH Pelikanstr. 13 Hannover30177 Germany

Immersed tumbling is an industrially established process for finishing of components made of metal, ceramic or plastic. In this process, the components are completely surrounded by a wet, abrasive medium, which allows burrs to be removed and surfaces to be polished. In order to gain specific insights into the influence and flow properties of the abrasive media used in this process, numerical approaches using the Discrete Element Method (DEM) with the Rocky DEM software are presented within these investigations. A complete process simulation could be realised by means of a digital machine tool. The immersed tumbling process with cone-shaped polymer abrasive media is implemented by use of a liquid bridge model. The results were validated by experiments with an industrially used immersed tumbling machine tool and for the first time allow sound statements about the contact conditions and interactions of the abrasive media with the workpiece. © 2021 Elsevier B.V.. All rights reserved.

关键词： Finite difference method

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Improvement of fatigue strength in heavy steel offshore-constructions through arc brazing 30

Improvement of fatigue strength in heavy steel offshore-cons...

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30th International Ocean and Polar Engineering Conference, ISOPE 2020

作者： Gericke, Andreas Drebenstedt, Karl Kuhlmann, Ulrike Henkel, Knuth-Michael Fraunhofer Institute for Large Structures in Production Engineering Department for Welding Engineering Germany University of Stuttgart Institute of Structural Design Germany University of Rostock Department for Joining Technology Germany

ISBN: (纸本)9781880653845

The possibility of arc brazing for attachments with the filler material CuAl7 instead of welding in heavy steel construction was investigated. The notch effect under cyclic loading was significantly reduced for arc brazed bushings and therefore the fatigue strength improved. In comparison to samples with welded attachments, the fatigue strength of samples with arc brazed attachments could be increased up to a fatigue class of FAT112. As a result of tests series, where only one parameter differed, the following influences could be concluded: An increasing stress ratio leads to decreased fatigue strength. No reduction of the fatigue strength was observed for thicker plates. For plates of high strength steel the same increased fatigue strength was confirmed on with arc brazed attachments as for mild steels. Microstructural analysis tests showed, that the dimension of the heat affected zone was reduced through reduced heat input. The appearance of liquid metal penetration was observed over the interface between filler material and base metal, which obviously had no negative effect to fatigue strength. Measurements of residual stresses in the weld / braze toe area showed that tensile residual stresses have not significantly been reduced. Numerical analysis showed that compared to a welded detail, the stress concentrations on the weld toe of the arc brazed fillets drop significantly due to the lower E-modulus of the alloy and therefore attract less forces due to the reduced stiffness leading to more favourable behavior under fatigue loading. The testing of the load bearing capacity of arc brazed bushings showed that high tensile stresses, which are comparable to the strength of the base metal, can be reached before fracture and that this detail is therefore suitable for applications in steel construction. © 2020 by the International Society of Offshore and Polar Engineers (ISOPE).

关键词： Copper alloys

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Wear behaviour of various CVD diamond thick film specifications during turning Ti-6Al-4V

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Procedia CIRP 2021年 101卷 266-269页

作者： Eckart Uhlmann Danny Schröter Institute for Machine Tools and Factory Management (IWF) Technische Universität Berlin 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) 10587 Berlin Germany

Due to the specific mechanical and thermal properties of Ti-6Al-4V, such as its high heat resistance, the suitability of certain cutting materials is adversely affected. However, the high thermal conductivity and wear resistance of CVD diamond thick films provide the possibility for machining these materials. The present study investigates the wear behaviour of different CVD diamond thick film specifications at various cutting *** particular, differences in the process forces of 53% due to the CVD diamond thick film specifications as well as deviations in tool stability due to process parameter dependent cracks or wear progress were observed.

关键词： diamond tool titanium turning

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AI-enhanced Identification, Inspection and Sorting for Reverse Logistics in Remanufacturing 28

AI-enhanced Identification, Inspection and Sorting for Rever...

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28th CIRP Conference on Life Cycle Engineering, LCE 2021

作者： Schlüter, Marian Lickert, Hannah Schweitzer, Katharina Bilge, Pinar Briese, Clemens Dietrich, Franz Krüger, Jörg Fraunhofer Ipk Institute for Production Systems and Design Technology Pascalstr. 8-9 Berlin10587 Germany Technische Universität Berlin Institute for Machine Tools and Factory Management Pascalstr. 8-9 Berlin10587 Germany Acatech-Deutsche Akademie der Technikwissenschaften Karolinenplatz 4 München80333 Germany

In a circular economy for remanufacturing, after each life cycle used products are returned to a remanufacturer for identification, inspection, sorting and reprocessing. Shortcomings and requirements of the remanufacturing market are identified through expert interviews and process analysis. A concept is proposed to enable an improved identification and a more objective inspection by enhancing the working environment and processes of sorting stations. Digitization and machine learning are applied on business data, using machine vision as well as sensor and actor skills of the worker. With an experimental case study on visual object recognition a positive impact on identification and thus sorting could be demonstrated. © 2021 Elsevier B.V.. All rights reserved.

关键词： Computer vision

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Investigation on stereo-ToF data fusion for the inspection of used industrial parts

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AIP Conference Proceedings 2024年第1期2989卷

作者： Oliver Krumpek Marian Schlüter Johannes Hügle Department of Machine Vision Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany

Optical systems for automated or partially automated inspection have been making important contributions to ensure the quality and functionality of technical products for many years. Often used to monitor the quality of newly produced goods, vision systems also aim to play an important role in identification and condition description of used industrial parts such as aged vehicle components. In this work, a passive stereo system and a Time-of-Flight (ToF) sensor of the latest generation were used to create the desired sensor system. In the first step, the pixel-based information of both sensors was exploited to spatially calibrate the transformation between the left stereo camera and the ToF sensor by forming a 2D-3D correspondence set of detected feature points. To compensate for the resolution difference of the sensors, numerous interpolation points were randomly sampled on the reconstructed sparse surface mesh of the ToF sensor to create the missing sub-pixel information. It could be shown that the fused sensor information led to an increase in incompleteness by 7.81% on average for all components examined. The higher noise in the ToF measurement data in the fill-ins could be mitigated by using an adapted median kernel filtering. The average deviation of the measurement from a reference dataset was 1.30mm for the stereo system, 2.51mm for the ToF system, and 1.42mm for the fused result. The result of this work is promising as the quality of the surface mesh could be raised especially for critical surface areas and the underlying RGB data itself can be used for pixel-wise classification and segmentation.

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Comparison of Resistive and Optical Strain Measurement for Early Fracture Detection

Comparison of Resistive and Optical Strain Measurement for E...

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作者： Carabello, Alina Neupetsch, Constanze Werner, Michael Rotsch, Christian Drossel, Welf-Guntram Zajonz, Dirk Chemnitz University of Technology Adaptronics and Lightweight Design in Production Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Iwu Chemnitz/ Dresden Germany Zeisigwaldkliniken Bethanien Chemnitz Germany

To increase learning success in surgical training, physical simulators are supplemented by measurement technology to generate and record objective feedback and error detection. An opportunity to detect fractures following hip stem implantation early can be measurement of occurring strains on bone surface. These strains can be determined while using strain gauges, digital image correlation (DIC) or photoelasticity. In this research strain gauges and DIC were compared regarding their suitability as strain measurement tools for use in physical simulators. Therefore a testing method was described to replicate the implantation of a hip stem. Testing devices modelled on a realistic prosthesis were pressed into prepared porcine femora in a two-step procedure with a material testing machine. The local strains occurring on bone surface were determined using an optical measurement system for DIC and strain gauges. The initial fractures in the tested femora are located medial-anterior in most cases (73,6%). With increasing indentation depth of the test device, the strains on bone surface increase. Comparing the local strains determined by DIC and strain gauges consistencies in curves are noticeable. Maximal determined strains before fracturing amount to 0,69% with strain gauges and 0,75% with DIC. In the range of the fracture gap, strain gradients are determined by using DIC. However the detected surfaces are of low quality caused by gaps and motion artefacts. The results show strains on bone surfaces for early fracture detection are measurable with strain gauges and DIC. DIC is assessed as less suitable compared to strain gauges. Furthermore strain gauges have greater level of integration and economic efficiency, so they are preferred the use in surgical training simulators. © 2020 by Walter de Gruyter Berlin/Boston 2020.

关键词： Image correlation

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Generative 3D Reconstruction of Ti-6Al-4V Basketweave Microstructures by Optimization of Differentiable Microstructural Descriptors

SSRN

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SSRN 2024年

作者： Blümer, Vincent Safi, Ali Reza Soyarslan, Celal Klusemann, Benjamin Boogaard, Ton van den Nonlinear Solid Mechanics University of Twente Drienerlolaan 5 Enschede7522 NB Netherlands Institute of Material and Process Design Helmholtz-Zentrum Hereon Max-Planck-Straße 1 Geesthacht21502 Germany Fraunhofer Innovation Platform Hengelosestraat 701 Enschede7521 PA Netherlands Institute for Production Technology and Systems Leuphana University Universitätsallee 1 Lüneburg21335 Germany Institute of Product and Process Innovation Section of Applied Mechanics

We present a methodology for the generative reconstruction of 3D microstructures from 2D cross-sectional electron backscatter diffraction micrographs. The method is applied to Ti-6Al-4V processed by laser powder bed fusion, where a high amount of basketweave morphology is observed, which arises from the solid-state β → α-transition upon cooling. Prior-β-grain reconstruction is performed and the out-of-plane orientation of the observed grains is obtained leveraging Burgers orientation relationship. Convolutional neural network - based microstructural descriptors are extracted from the 2D micrographs, and used for cross-section-based optimization of pixel values in a 3D volume. In order to reconstruct crystallographic orientations, the orientation distribution of the basketweave microstructure is reduced to a discrete set of characteristic orientations, which are sequentially reconstructed as separate components. Our reconstructions capture the characteristic lath morphology that is typically observed in powder bed fusion-processed Ti-6Al-4V and perform well in comparisons of chord length-, as well as grain size-, aspect ratio-, and axis orientation distributions. © 2024, The Authors. All rights reserved.

关键词： Aspect ratio

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Development of a machining strategy for diamond slide burnishing burnishing tools made of polycrystalline diamond (PCD) 20

Development of a machining strategy for diamond slide burnis...

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20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020

作者： Uhlmann, E. Polte, M. Polte, J. Kuche, Y. Wendorf, S. Siebel, D. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany Baublies AG Renningen Germany

ISBN: (纸本)9780995775176

High demands on product quality force companies to reduce production costs. Due to the growing international competition, optical surfaces for tool and mould making need to be produced economically. These surfaces are commonly produced using ultra-precision cutting. However, the efficiency is limited due to low feed velocities vf, small depth of cut ap and associated long process times tPr. An innovative manufacturing process represents diamond burnishing, which can be carried out directly after the high-precision milling process. For this purpose, super-hard materials made of single crystalline diamond (SCD) are currently used as tool materials. Since the material costs are high and the availability is limited, SCD needs to be substituted. An innovative substitution material is polycrystalline diamond (PCD). Within this paper, a machining strategy for the high-precision production of PCD spheres for diamond slide burnishing tools is presented. The processes grinding, polishing and electrical discharge machining (EDM) were applied. Therefore, the manufacturing costs, the surface roughness, the shape accuracy as well as the concentricity accuracy were analysed. Based on these investigations, an efficient and economical machining strategy for the production of high-precision spherical geometries made of PCD can be provided. First results showed that the prefered machining strategy uses a cross-process chain consisting of grinding and polishing. Thereby, the advantages of both processes with the fast manufacturing of the macro-geometry by the grinding process as well as the high surface qualities, which can be achieved by the polishing process, are combined. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Surface roughness

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