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30th CIRP design on design, CIRP design 2020

作者： Petrusch, Natalie Schliephack, Wolf Kohl, Holger Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin10587 Germany Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

Shortening product life cycles and increasing, global competition lead to the necessity for companies to become flexible and able to change. The successful conduction of change projects depends to a large extent on the understanding and cooperation of the operating people. The acquisition of knowledge and thus of competence at all levels is of fundamental importance for this. Learning Factories are one of the most sustainable concepts in this respect. Concerning the industrial application, however, Learning Factories require high investment costs and are relatively inflexible in respect to their dedicated facilities and their learning content. This reveals a connection between the success of a Learning Factory in an industrial context and its mobility. In order to be able to evaluate approaches towards the mobility design of Learning Factories more precisely, the decisive drivers for mobility are identified. The assessment of these drivers with regard to the extent of influence on mobility, but also the critical consideration of possible limits, lead to an evaluation model for the mobility design of Learning Factories. Subsequently, this model is tested by applying it to a successfully operating Learning Factory. © 2017 The Authors. Published by Elsevier B.V.

关键词： Life cycle

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Concept and Architecture for Information Exchange between Digital Twins of the Product (CPS) and the production system (CPPS) 54

Concept and Architecture for Information Exchange between Di...

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54th CIRP Conference on Manufacturing Ssystems, CMS 2021

作者： Vogt, Anna Müller, Ralph Klaus Kampa, Thomas Stark, Rainer Großmann, Daniel Technical University of Berlin Department Industrial Information Technology Pascalstraße 8-9 Berlin10587 Germany Audi AG Auto-Union-Str. 1 Ingolstadt85045 Germany Technische Hochschule Ingolstadt Esplanade 10 Ingolstadt85049 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany

The Digital Twin concept and CPS- and IIoT-based approaches are increasingly important topics concerning future Industry 4.0 architectures. They offer high potential for dynamical aspects in intelligent production planning and control as well as part traceability and documentation. Standardized information exchange is an upcoming requirement among the whole supply chain. This paper presents a concept for a Digital Twin architecture based on motor production in the automotive industry. The key aspect is an information exchange structure for Digital Twins of products and production systems that are combined using principles of Dynamic Aggregation. © 2021 The Author(s).

关键词： Cyber Physical system

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Application of additive manufactured tungsten carbide-cobalt electrodes with interior flushing channels in S-EDM

Application of additive manufactured tungsten carbide-cobalt...

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20th CIRP Conference on Electro Physical and Chemical Machining, ISEM 2020

作者： Uhlmann, Eckart Polte, Julian Bolz, Robert Yabroudi, Sami Streckenbach, Jan Bergmann, André Fraunhofer Institute for Production Systems and Design Technology Pascalstrasse 8-9 Berlin10587 Germany Technische Universität Berlin Chair of Machine Tools and Manufacturing Technology Pascalstrasse 8-9 Berlin10587 Germany

Application fields of electrical discharge machining (EDM) are limited due to given process conditions. Manufacturing of parts with high aspect ratios and the application of multi-axis machining are limited due to process instabilities caused by removed particles. A promising approach to improve EDM process conditions, especially in sinking EDM (S-EDM), is the utilization of flushing channels in the tool electrode. However, with increasing complexity of the tool electrode geometry and the local integration of these flushing channels, conventional tool electrode manufacturing by cutting is limited. In contrast to that, the machining process selective laser melting (SLM) does not have such limitations. The appropriate integration of flushing channels, even for complex electrode geometries, improves process conditions during EDM in a variety of applications. This leads to a higher material removal rate and reduced tool wear compared to machining without flushing. Additionally, the number of required tool electrodes can be reduced, as SLM enables an efficient integration and miniaturization of all features in a single electrode. Because of its wear resistance and stability, tungsten carbide is an ideal tool electrode material, which is commonly applied in drilling EDM. After identifying suitable process parameters for roughing EDM with additively manufactured tungsten carbide cobalt tool electrodes, different forms of flushing channels were analysed in order to establish a fast process with minimum tool electrode wear. The results concerning material removal rate and the relative tool wear could be improved by applying internal flushing, though the tool wear stayed at a worse level compared to conventional tool electrode materials. © 2020 The Authors. Published by Elsevier B.V.

关键词： Tungsten carbide

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Measurement and Modeling of Contact Forces during Robot-guided Drag Finishing

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Procedia CIRP 2021年 102卷 518-523页

作者： Eckart Uhlmann Marco Kopp 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

Robot-guided drag finishing is a free abrasive grinding operation that is used for polishing and deburring of workpieces with complex shaped geometries. The workpiece is attached to a robot and moved through a bulk of abrasive particles. The motion of abrasive particles during contact with the workpiece is the basis of the material removal mechanisms. To investigate the motion of abrasive particles during contact, a force measurement system was used to determine contact forces. The experimental setup was replicated in a numerical simulation based on the discrete element method (DEM). Based on the comparison of experimental and simulative results the qualitative validity of the DEM model was concluded. With the presented DEM model, the characteristic particle behavior during contact with the workpiece can be modeled which allows the prediction of resulting processing marks. Consequently, the DEM model can be used to design free abrasive grinding operations without using the time and cost intensive trial and error approach.

关键词： robot-guided drag finishing discrete element method process design validation contact forces

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Numerical investigation on the process behavior of a closed-loop internal cooling system for turning operations

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Procedia CIRP 2021年 102卷 73-78页

作者： E. Uhlmann P. Meier 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

The development of sustainable manufacturing processes and the associated reduction of operating materials such as cooling lubricants represent key focuses on recent production technology. Thus, a novel tool system with a closed-loop internal cooling system for turning operations is presented in this study. The system design is based on numerical investigations of the heat flow Q⋅ with consideration of the thermomechanical load of the cutting tool and flow characteristics of the cooling fluid. The process behavior of the proposed system shows a significant dependence of the flow rate V⋅ and tool thickness t T in terms of tool temperature reduction Δθ T .

关键词： Turning Cooling Sustainable manufacturing

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Prediction of temperature distribution in diamond cutting tools during machining Ti-6Al-4V

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Procedia CIRP 2021年 102卷 37-42页

作者： E. Uhlmann D. Schröter V.H. Wohlfahrt 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

The high thermal conductivity and wear resistance of CVD diamond provide potential for the machining of Ti-6Al-4V. By predicting thermomechanical loads, simulations can provide information about the usability of these cutting materials. However, the occurring shear chip formation within the cutting process leads to unsteady contact conditions. Therefore, a computationally intensive long-term transient simulation is necessary for precise prediction of tool temperatures. In this respect, a user-subroutine has been developed, allowing a high-resolution long-term simulation with acceptable computing time. By experimental investigations and validation of simulated results, a modelling of temperature distribution within the cutting tool is possible, providing valuable information regarding the contact temperatures.

关键词： titanium diamond tool turning temperature

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Micro-texture trajectory dependent pressure distribution of CVD diamond thick film cutting tools during turning of Ti-6Al-4V

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Procedia CIRP 2021年 102卷 49-54页

作者： E. Uhlmann D. Schröter 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

To counteract the high thermomechanical load during turning Ti-6Al-4V, an advancement of tool geometries is necessary. Based on simulative and empirical analysis, the present study investigates the process behaviour of micro-textured CVD diamond cutting tools. Different micro-texture trajectories determine influence of the microstructure on the stress levels, pressure distributions and adhesive wear. Compared to non-textured cutting tools, a cutting force reduction of 12.8 % determined empirically and 19.5 % determined simulatively with simultaneous displacement of the principal stress results using micro-textures. Based on simulatively calculated process forces and pressure distributions an evaluation of tool stability and adhesion tendency is possible.

关键词： diamond tool texture finite element method (FEM) titanium turning

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Improvement of Charpy impact toughness by using an AC magnet backing system for laser hybrid welding of thick S690QL steels

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Procedia CIRP 2022年 111卷 462-465页

作者： Ömer Üstündag Nasim Bakir Andrey Gumenyuk Michael Rethmeier Bundesanstalt für Materialforschung und -prüfung (BAM) Unter den Eichen 87 12205 Berlin Germany 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

The study deals with the influence of the heat input and the resulting cooling times on the microstructure and Charpy impact toughness of single-pass laser hybrid welded 20-mm thick high-strength steel S690QL. The main focus is on the change of the mechanical properties over the entire seam thickness. The cooling times were measured in-situ using a pyrometer and an optical fibre in three different depths of the seam where Charpy impact test specimens were also later taken. Thereby, three different heat inputs from 1.3 kJ/mm to 2 kJ/mm were investigated. Despite the observed decreased values of both t 8/5 -cooling time and the Charpy impact toughness in the root part of the seam, the required impact toughness of 38 J/cm 2 could be reached in dependance on applied heat input, especially at the heat input of 1.6 kJ/mm.

关键词： laser hybrid welding AC magnet backing Charpy impact toughness high-strength steel S690QL

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Automotive hybrid design production and effective end machining by novel abrasive waterjet technique

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Procedia CIRP 2021年 101卷 374-377页

作者： M. Schüler D. Heidrich T. Herrig X.F. Fang T. Bergs Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 52074 Aachen Germany University of Siegen - Institute of Automotive Lightweight Design Breite Strasse 11 57076 Siegen Germany Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany

Hybrid designs with the combination of metal and long fiber reinforced thermoplastics (LFT) offer a great opportunity to reduce component weight for automotive applications. production costs are typically high due to complex processes and challenging end machining. A complete manufacturing process chain for simultaneous hybrid design production is presented. Hybrid forming, a manufacturing process combining metal sheet forming, LFT compression molding and bonding, was developed to manufacture an automotive lightweight component, finally end machined by innovative waterjet techniques. Besides optimizing waterjet end machining strategies, waterjet controlled-depth machining was used to remove LFT material selectively, resulting in increased hybrid production flexibility.

关键词： Waterjet machining Abrasion Abrasive Properties

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Environmental and technical evaluation of additive manufacturing: Enabling process chain perspective by energy value stream mapping

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Procedia CIRP 2022年 105卷 440-445页

作者： Mathias Wiese Christopher Rogall Nadja Henningsen Christoph Herrmann Sebastian Thiede Polymer Additive Manufacturing Center AUDI AG Auto-Union-Straße 1 Ingolstadt 85045 Germany Chair of Sustainable Manufacturing and Life Cycle Engineering Institute of Machine Tools and Production Technology Technische Universität Braunschweig Langer Kamp 19b Braunschweig 38106 Germany Fraunhofer Institute for Surface Engineering and Thin Films (IST) Bienroder Weg 54 E Braunschweig 38108 Germany Manufacturing Systems Faculty of Engineering Technology Department of Design Production & Management University of Twente De Horst 2 Building 20 Enschede 7522 LW The Netherlands

Additive manufacturing (AM) currently evolves from a prototyping process to an alternative manufacturing process for end-use parts, advancing into fabrication of low to medium product volumes. Moreover, increasing awareness of environmental impacts of manufacturing lead to the necessity of holistic evaluation among traditional evaluation criteria in the technical and economic domains. However, existing evaluation approaches seldom consider a complete AM process chain and are lacking a production-oriented notation which enables comparability across technologies and support in identification of improvement potentials on technical and environmental level. To address this gap, this paper highlights the way from structured data acquisition to setup of an energy value stream map (EVSM) for AM process chains in end-use part production, augmenting methods of lean manufacturing by the energy dimension. Consequently, it contributes to a holistic and transparent process chain perspective to assess AM as a manufacturing alternative. The proposed methodology is applied to a case study covering two different process chains, a first based on powder bed fusion via Multi-jet Fusion (MJF) and a second utilizing vat-photopolymerization via Continuous Liquid Interphase Printing (CLIP). While the MJF process chain’s energetical hot spot is situated in the printing process itself, the hot spot for CLIP is found in thermal post-processing, exceeding the comparably efficient printing process by magnitudes and ultimately resulting in higher energy intensity per part compared to the MJF process chain. These results highlight the necessity of a holistic evaluation method for complete AM-based process chains and their influence on the product properties. Insights may help engineers, designers and decision makers in pre-selection of suitable manufacturing strategies with a more complete view on AM process chains.

关键词： Additive manufacturing rapid manufacturing process chains value stream mapping sustainable manufacturing decision support

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