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37th Annual Meeting of the American Society for Precision Engineering, ASPE 2022

作者： Uhlmann, Eckart Polte, Mitchel Hörl, Robert Braun, Thomas Bolz, Robert Technische Universität Berlin Institute for Machine Tools and Factory Management Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

ISBN: (纸本)9781887706568

Increasing product complexity and continuous developments in related tool and mould making industry require ongoing advances in manufacturing processes like electrical discharge machining (EDM). To meet the increasing requirements, the development of adapted EDM processes and tool designs is necessary. Additive manufacturing (AM) enables the manufacturing of complex tool electrode geometries with interior flushing channels for EDM processes with very few restrictions regarding the design. This accounts even for tungsten carbide-cobalt (WC-Co), which is a suitable material for EDM tool electrodes with various advantages, e.g. thermal and mechanical stability. This paper shows first results of additive manufactured WC-Co tool electrodes for the use in sinking EDM and the related development process. © 2022 Proceedings - ASPE 2022 Annual Meeting. All right reserved.

关键词： Additives

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Framework of an experimental setup to enable an adaptive process control based on surrogate modelling 22

Framework of an experimental setup to enable an adaptive pro...

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

作者： Uhlmann, E. Polte, J. Bösing, M. Schuler, N. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9781998999118

Numerical simulations can help to reduce the necessity of experimental studies. Nevertheless, these simulations are costly in terms of their computational effort resulting in significant expenditure of time and hence prevent a flexible adaption to continuously changing process conditions in real time. To address this shortcoming, the paper describes a framework for the application of surrogate models to enable an adaptive process control in real time. Following, an experimental setup to validate the general framework is designed for a laser metal deposition process. In particular, the component distortion shall be simulated and the results are then used to train the surrogate models. By measuring the final component distortion the quality of the surrogate models can be assessed. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Process control

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Zirconium dioxide-reinforced aluminium oxide ceramic for micro-milling of graphite 22

Zirconium dioxide-reinforced aluminium oxide ceramic for mic...

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

作者： Uhlmann, E. Polte, M. Polte, J. Hocke, T. Wendt, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9781998999118

Tool and mould making is one of the most important sectors for production of complex parts with highest economic efficiency. Particularly the milling process is a key technology for the manufacturing of tool electrodes for electrical discharge machining (EDM). Beside copper, graphite is the most industrial relevant tool electrode material for sinking-EDM. According to the state of the art the machining of graphite results in high tool wear in consequence of strong chemical and abrasive effects. Currently, uncoated and cost intensive diamond coated cemented carbide tools are used for industrial applications. High tool costs and short tool life have a negative impact on the economic efficiency of the manufacturing process and increase the overall production costs. To reduce the production costs, the needs for innovative cutting materials and dedicated manufacturing processes are high. The zirconium dioxide-reinforced aluminium oxide ceramic used in this investigation shows a great potential because of the high hardness H, the missing binder phase and the covalent bond. The aim of this investigation is the examination of the application behaviour of ceramic cutting tools during the machining process of graphite. Therefore, dedicated milling tests in partial and full cut were carried out. For evaluation of the application behaviour of the ceramic tools, the surface quality of the machined graphite depending on the wear of the tools was considered. The results show that a minimum surface roughness of Ra = 0.80 µm and average surface roughness of Rz = 6.55 µm could be achieved in first milling tests. Due to a strong sharpening effect of the cutting edge during the machining, the possibility was provided to produce complex components with highest precision and without chipping behaviour. The machining of graphite using ceramic milling tools shows extensive advantages compared to conventional milling tools, which may positively affect the economic efficiency of machining gr

关键词： Milling (machining)

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Joint Parameter and State-Space Modelling of Manufacturing Processes using Gaussian Processes

Joint Parameter and State-Space Modelling of Manufacturing P...

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IEEE International Conference on Industrial Informatics (INDIN)

作者： Saksham Kiroriwal Julius Pfrommer Hendrik Mende Robert H. Schmitt Jurgen Beyerer Fraunhofer Institute of Optronics System Technologies and Image Exploitation IOSB Germany Fraunhofer Institute of Production Technology IPT Germany WZL: Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Karlsruhe Institute of Technology Germany

ISBN: (数字)9798331527471

ISBN: (纸本)9798331527488

Manufacturing process optimization is an open question, where Bayesian decision theoretic methods have shown considerable promise. One such is Bayesian optimization, with Gaussian Process (GP) surrogate model. This paper explores Gaussian Processes networks to jointly use parameter and observed state to predict the output(s) of a manufacturing process. The Gaussian process network that represents the paths from parameters to state-space to tasks, provides a methodology to ‘look inside’ the black-box of complex manufacturing processes. We present a comparative analysis of this method against the multi-task Gaussian processes and single-task counterparts, highlighting the benefits and drawbacks of each in modelling the behavior of such processes. We show the benefits of the proposed approach using numerical experiments. We show that we are able to improve the output prediction by additional sensor observations from inside the process at training time without needing those sensor observations for predicting product quality given the process parameters.

关键词： Training Manufacturing processes Gaussian processes Multitasking Product design Numerical models Bayes methods Quality assessment Informatics Optimization

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Two-colour thermography for measurement of temperature distribution in laser beam welding 13

Two-colour thermography for measurement of temperature distr...

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13th CIRP Conference on Photonic Technologies, LANE 2024

作者： Gumenyuk, A. Bakir, N. Rethmeier, M. Unter den Eichen 87 Berlin12205 Germany Technische Universität Berlin Pascalstrasse 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 Berlin10587 Germany

Solidification cracking is a frequently observed phenomenon in laser beam welding of austenitic stainless steels and other metallic alloys. Characterisation of cracking susceptibility requires knowledge of the precise and spatially resolved temperature distribution near the solidification front in the welding process. Thermography is a standard tool that provides a qualitative estimate of the 2D temperature field. The general disadvantage of this method is its dependence on the emission characteristics of the measured object. For welding applications, these can vary significantly in the temperature range above and below the melting temperature. For this purpose, we have developed a thermography-based measurement technique using a SWIR camera system in combination with two narrow bandpass filters that use the principle of two-wavelength pyrometry to estimate absolute temperature values. This technique was used to determine the temperature distributions and gradients near the solidification front of laser-welded austenitic steel. The results were validated by other measurements. © 2024 The Authors.

关键词： Laser beam welding

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Prediction of Quality in Thermographic Spray Spot Applications with Machine Learning Algorithms 56

Prediction of Quality in Thermographic Spray Spot Applicatio...

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56th CIRP International Conference on Manufacturing systems, CIRP CMS 2023

作者： Uhlmann, Eckart Polte, Julian Koutrakis, Nikolaos-Stefanos Pyka, Lasse Ider, Müslüm Thomas, Georg Rupprecht, Christian Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

Due to the high number of influences in production applications, quality fluctuation and deviating results in thermal spray applications are a challenging issue in manufacturing processes. This paper presents a concept for an adaptive process control based on different machine learning algorithms that are utilized to correlate input parameters with output results in thermal spray processes. For that purpose, a test environment was developed, incorporating different application scenarios with various input parameters. During the experiments, a series of measurements was performed, that is used to describe and evaluate the process. The extracted data of the conducted experiments are transformed into features and serve as the data input for the development of machine learning models based on various algorithms. These algorithms offer a prediction of the peak position, which describes the deviation of the programmed application spot, thus offering a quality prediction by utilizing solely the input process parameters. This work provides an approach based on the compared algorithms, that can be applied to create an adaptive process control, by adjusting the input parameters during the thermal spray application 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) Peer-review under responsibility of the scientific committee of the 56th CIRP International Conference on Manufacturing systems 2023.

关键词： Machine learning process control quality prediction thermal spray process

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ABRASIVE PROPERTIES OF MAGNETO-RHEOLOGICAL FLUIDS FOR IMMERSED TUMBLING PROCESSES 38

ABRASIVE PROPERTIES OF MAGNETO-RHEOLOGICAL FLUIDS FOR IMMERS...

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38th Annual Meeting of the American Society for Precision Engineering, ASPE 2023

作者： Sordon, Fabian Ludwig, Jonas Schreiner, Valentin Hocke, Toni 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)9781887706599

Micro-milling tools, widely used in industrial environments for manufacturing micro- and precision components, experience premature tool failure primarily due to cutting edge wear. In immersed tumbling processes, the cutting edges can be post-processed to gain homogeneous edge radii and reduce the tool wear. However, immersed tumbling processes exhibit limitations in the adjustability of the cutting edge geometry as well as difficulties in the directed processing of main and secondary cutting edges. Therefore, a novel immersed tumbling process using magnetorheological fluids (MRF) is investigated to enable a directed processing method in an applied magnetic field. The focus of this work is to identify a suitable composition of the MRF for an increased abrasive effect on high-speed steels. For this purpose, variously composed MRF samples are blended with abrasive particles and then examined using a custom-designed test bench that replicates the immersed tumbling process. The material removal rate on high-speed steel specimens is determined by optical analysis of the edge rounding of the samples before and after the abrasive process in order to find an optimized abrasive MRF composition with the highest material removal rate on high-speed steels. © 2023 Proceedings - ASPE 2023 Annual Meeting. All rights reserved.

关键词： Magnetorheological fluids

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F5G OpenLab: Enabling Twin Transition through Ubiquitous Fiber Connectivity

F5G OpenLab: Enabling Twin Transition through Ubiquitous Fib...

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International Conference on Transparent Optical Networks

作者： Mihail Balanici Behnam Shariati Pooyan Safari Paul Chojecki Moritz Chemnitz David Przewozny Johannes Karl Fischer Ronald Freund Fraunhofer Institute for Telecommunications Heinrich-Hertz-Institut Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

The paper introduces a new open laboratory, the F5G OpenLab, which aims at fostering the advancement of fiber-based solutions for everything. F5G OpenLab intends to aid in creating a sustainable and eco-friendly ICT industry and accelerate the digital transformation through autonomous networking solutions that are secure and trustworthy. In particular, the purpose of the F5G OpenLab is to establish an ecosystem for the validation of optical networking solutions that facilitate twin transition, provide a vendor-neutral platform for the assessment of vertical use cases, and enable the development of fiber-based solutions. It provides a platform to verify and unify next-gen networking solutions, access to early hardware and software releases, and unique testing and measurement facilities. Finally, the F5G OpenLab supports the development of blueprints for a green and digital transformation, capitalizing on the benefits of fiber technology for all industry sectors. We present its architecture as well as key features and capabilities. Moreover, we report several proof-of-concept demonstrations focused on industry 4.0 vertical use-cases.

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Experimental Investigations of the Preload-time-behaviour of Lockstud systems Enhanced by Finite Element Analysis 34th

Experimental Investigations of the Preload-time-behaviour of...

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34th International Ocean and Polar Engineering Conference, ISOPE 2024

作者： Hagemann, Melanie Schwarz, Mathias Schröder, Markus Blunk, Christoph Glienke, Ralf Schwerdt, Daniela Henkel, Knuth-Michael University of Applied Sciences Technology Business and Design Wismar Germany Fraunhofer-Institute for Large Structures in Production Engineering IGP Rostock Germany Howmet Fastening Systems-Industrial Fastener Division Telford United Kingdom University of Rostock Faculty of Mechanical Engineering and Marine Technology Chair of Joining Technology Rostock Germany

ISBN: (纸本)9781880653784

This article presents current results on the initial preload of Lockstud systems of nominal sizes M12 to M20, property class 8.8 and 10.9 in uncoated black, zinc flake coated and hot-dip galvanised conditions during the assembly process. In addition, it provides design recommendations for the preload as given in accordance with Technical Bulletin DVS/EFB 3435-2. Comprehensive numerical investigations of Lockstud systems have shown validated simulations of the assembly process, including the resulting preload (2D model), the stress concentrations with critical failure locations (3D model) and additionally the slip load of a slip-resistant connection (3D model). © 2024 by the International Society of Offshore and Polar Engineers (ISOPE).

关键词： Finite element method

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Improved lifetime estimation of shot-peened shaft bores using a numerical approach

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Procedia Structural Integrity 2024年 57卷 411-419页

作者： Felix-Christian Reissner Lars Uhlmann Jörg Baumgartner Tim Herrig Thomas Bergs Fraunhofer Institute for Structural Durability and System Reliability (LBF) Bartningstr 47 64289 Darmstadt Germany Laboratory for Machine Tools and Production Engineering (WZL) Campus-Boulevard 30 52074 Aachen Germany Fraunhofer Institute for Production Technology (IPT) Steinbachstr. 17 52074 Aachen Germany

Shot peening is commonly used to improve the fatigue strength of mechanical components. The peening process involves the use of high-energy mechanical impacts to create compressive residual stresses and a material hardening on the surface of the component, which can significantly increase its resistance to fatigue. Accurate lifetime prediction is important for optimizing the design of shot-peened components and ensuring their reliability and safety. Due to nonlinear material behavior and the simulation of contact, estimating the lifetime of shot-peened shaft bores under cyclic loading conditions remains a challenge. In this study, the lifetime estimation of shot-peened shaft bores using a combination of experimental testing and finite element analysis is investigated. A series of experiments was conducted on shot-peened shaft bores made of EN-GJS-700 and 34CrNiMo6, using different peening parameters such as intensity and coverage. The specimens with shot-peened shaft bores were subjected to cyclic loading in a fatigue testing machine and the lifetime was experimentally identified. The results were used to develop a methodology based on finite element analysis, which considers the effect of the shot peening parameters on the residual stress distribution, hardening and the resulting fatigue life. The results of the proposed methodology were validated against the experimental data and showed good agreement with the experimental results. The derived methodology can be used to estimate the lifetime of shot-peened shaft bores under different loading and peening conditions and provides a useful tool for optimizing the design of shot-peened components in fatigue engineering applications.

关键词： shot peening lifetime estimation residual stress finite element analysis cyclic loading

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