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

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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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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Towards Robot-Assisted Data Generation with Minimal User Interaction for Autonomously Training 6D Pose Estimation in Operational Environments

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Procedia CIRP 2023年 120卷 249-254页

作者： Paul Koch Marian Schlüter Serge Thill Jörg Krüger Fraunhofer Institute for Production and System Design Technology Pascalstraße 8-9 10587 Berlin Germany Donders Institute for Brain Cognition and Behavior Radboud University 6525 HR Nijmegen Netherlands Technical University Berlin Institute for Machine Tools and Factory Management Pascalstraße 8-9 10587 Berlin Germany

Recently, deep neural networks achieved state-of-the-art results in the subject of 6D object pose estimation for robot manipulation. However, those deep learning methods require expensive training data. Current methods for cost reduction use synthetic data, but rely on expert knowledge and suffer from the domain gap when shifting to the real application. Here, we present a proof of concept for a novel approach towards generating annotated training data for 6D object pose estimation. This approach is designed for learning new objects in operational environments while requiring little interaction and no expertise on the part of the user.

关键词： 6D Object Pose Estimation Artificial Intelligence Data Generation Robotic Grasping Robot Cognition

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

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Procedia CIRP 2022年 108卷 483-488页

作者： E. Uhlmann D. Schröter E. Gärtner 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 Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Machining titanium alloys such as Ti-6Al-4V results in a high thermomechanical load on cutting tools and consequently short tool lifes. With respect to a necessary reduction of the resulting cutting tool temperatures, ultrashort pulse (USP) laser fabricated micro-textured rake faces offer direct supply of cooling lubricant into the cutting zone and lead to a reduced heat induction. As a result, micro-textured CVD diamond thick film cutting tools are also capable of machining high-performance materials due to reduced contact temperatures. In the scope of the research, the resulting temperature distribution for micro-textured rake faces will be compared under both dry and wet process conditions. Measurements show a reduction of the resulting cutting tool temperatures of Δ ϑt = 27.9 % using micro-textured cutting tools compared to non-textured cutting tools. A validated simulation provides valuable information about the contact temperatures enabling a specific development of the micro-texture geometry. As a result, a reduction of the contact temperature between chip and rake face by Δ ϑ T = 24.7 % was possible.

关键词： diamond tool texture titanium turning temperature laser surface integrity

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An easy-to-use and cost-efficient fingertip exchange system for robot assembly tasks

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AIP Conference Proceedings 2024年第1期2989卷

作者： Ole Kroeger Jean-Paul Goppold Sebastian Mohr Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany

For handling in automated (robot-based) assembly processes, different gripper solutions are often required for different parts or process steps. In addition, introducing a new grasping solution can also be a time-consuming job. Previous solutions use e.g. specialized tool changing systems where the entire gripper system is exchanged to handle the variations of different parts, shapes and geometries. However, these systems are expensive and require an entire magazine of complete gripper systems. Therefore, in this paper we present a flexible, easy and cost-efficient fingertip exchange system. In this way, only one gripper is needed, as it can be used for many different fingertips. The system consists of a mechanical fingertip changing system, which can be installed on different (user-specific) gripper systems. In addition, we introduce a Parametrized Finger Method that automates the design for custom fingertips. Important process parameters such as the type of gripper kinematics, grasping force and max. length of the gripper fingers can be taken into account. The fingertips can then be manufactured cost-effectively with a 3D printer and fit perfectly to the individual objects. The system was benchmarked by the task-board task from the World Robot Challenge 2018 and with a UR5 robot. The average success rate of the automatically generated tips in this real-world scenario was 90 %.

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DEM-simulation of particle behaviour during cutting edge preparation of micro-milling tools by immersed tumbling 20

DEM-simulation of particle behaviour during cutting edge pre...

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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. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775176

The micro-milling process is widely used in industry for the manufacturing of complex geometries for a wide range of materials. To increase the tool life and cutting length the cutting edge preparation could be successfully established. Within preliminary investigations the immersed tumbling process was identified as the most promising process for cutting edge preparation of micro-milling tools. The process enables a reproducible cutting edge preparation with constant cutting edge radii as well as low chipping of the cutting edges. For a profound understanding of the preparation process and the process mechanisms further knowledge about the particle interactions with cutting tools as well as the particle flow mechanisms needs to be obtained. Therefore, the process simulation using discrete element methods (DEM) offers the possibility of an improved understanding of the process behaviour. In this investigation simulation studies about the cutting edge preparation of micro-milling tools using the immersed tumbling process will be presented. The DEM with the software ROCKY DEM from the company ESSS, Florianópolis, Brasil, was used and a process model was derived. The investigations show that the software can be successfully used for the visualisation of the immersed tumbling process and the flow mechanisms can be examined more closely. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Finite difference method

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CHALLENGES, DISPARITIES AND RISKS OF THE EUROPEAN INNOVATION ECOsystem: THE SPREAD2INNO PROJECT TO BRIDGE THE GAP

CHALLENGES, DISPARITIES AND RISKS OF THE EUROPEAN INNOVATION...

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74th International Astronautical Congress, IAC 2023

作者： D'Agostinis, Giorgia Scatena, Lorenzo Lombardi, Eleonora Singer-Coudoux, Katrin Buxmann, Henry Nicolai Konstantinopoulos, Panagiotis Haskovic, Damir Todorova, Ina Fondazione E. Amaldi c/o Italian Space Agency Rome Italy Business Applications Department Fondazione E. Amaldi c/o Italian Space Agency Rome Italy Research Associate Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Patras Science Park S.A. Patras Greece Research & Innovation Department MINDS & SPARKS GmbH Vienna Austria Cleantech Bulgaria Sofia Bulgaria

The European innovation ecosystem is experiencing global competition, while the support mechanisms for startups and SMEs are lacking capacity and cooperation. This situation results in financial challenges, regional disparities, and scaling-up risks. The SPREAD2INNO - SPREADing the global potential of developing innovation ecosystems to strengthen INNOvation in regional and local businesses - project aims to address these issues by implementing a comprehensive two-year program that provides high-quality business services and promotes collaboration between different entities in both well-connected and less-connected regional innovation ecosystems. The project brings together various innovation actors from crucial European innovation regions, including Germany, Belgium, Austria, Bulgaria, Greece, and Italy. The consortium of the project is composed of seven high-level business acceleration service providers from six different countries, with three from low/moderate innovation regions and three from strong/high innovation regions. The project's methodology is unique and interdisciplinary, aimed at improving entrepreneurial activities in less developed innovative regions, strengthening their acceleration capacity, and enabling entrepreneurs to scale their concept to a concrete solution with strong market potential. As a result, this will improve the development and competitiveness of these regions. The goal is to improve the capacity and competitiveness of both business accelerator institutions and SMEs and startups from more and less developed innovation ecosystems. Through the implementation of a range of activities that focus on developing a highly replicable, scalable, and holistic program for the provision of high-quality business services and collaboration between different entities of well-connected and less-connected regional innovation ecosystems. By doing so, the project hopes to create a sustainable and replicable model that can be easily adopted by the rest

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Increased efficiency and accuracy in ultra-precision machining through adapted CAM software 20

Increased efficiency and accuracy in ultra-precision machini...

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

作者： Uhlmann, E. Polte, J. Hein, C. Kuche, Y. Dörr, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775176

CAM software is widely used through the last 40 years for a broad field of applications. The networkability of machine tools and the digitally integrated production as an existing trend for the next years and exponentially increasing computing power enable direct data transfer between CAD/CAM software and machine tool. Increments ar Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Nanotechnology

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Development of monolithic ceramic milling tools for machining graphite 20

Development of monolithic ceramic milling tools for machinin...

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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. Hocke, T. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775176

Due to the international competition, continuous increases in productivity, product quality and reduction of production costs are required. Especially, the development of milling tools made of innovative cutting materials and application-specific tool geometries are in focus to overcome these challenges. Besides copper, graphite is the most important electrode material for electrical discharge machining (EDM). The machining of graphite leads to high tool wear due to a strong abrasive effect. Short tool life has a considerable influence on the economic efficiency of manufacturing processes. Currently, for the machining of graphite cost intensive diamond coated carbide tools are applied. In order to reduce machining costs, innovative cutting materials and dedicated manufacturing processes have to be applied. First results show a great potential of ceramics as tool material for machining graphite. The aim of this investigation is the characterisation and identification of novel ceramic cutting materials and the evaluation of an innovative tool micro-geometry especially designed for machining graphite. Therefore, the cutting material properties such as hardness, fracture toughness and wear resistance of four ceramic materials were investigated. Various hardness tests and particle blasting tests were carried out. Based on this investigations to manufacture the ceramic milling tools, a specific and innovative tool micro-geometry with defined angles was used. Thereby, a suitable cutting ceramic was identified, which represents a promising approach for an optimised machining of graphite. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Graphite

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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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