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arXiv 2022年

作者： Thiele, Gregor Johanni, Theresa Sommer, David Krüger, Jörg Department for Process Automation and Robotics Fraunhofer Institute for Production Systems and Design Technology IPK Germany Faculty of Electrical Engineering and Computer Science Technical University of Berlin Berlin Germany Weierstrass Institute for Applied Analysis and Stochastics Berlin Germany Institute for Machine Tools and Factory Management Technical University of Berlin Berlin Germany

The operation of industrial facilities is a broad field for optimization. Industrial plants are often a) composed of several components, b) linked using network technology, c) physically interconnected and d) complex regarding the effect of set-points and operating points in every entity. This leads to the possibility of overall optimization but also to a high complexity of the emerging optimization problems. The decomposition of complex systems allows the modeling of individual models which can be structured according to the physical topology. A method for energy performance indicators (EnPI) helps to formulate an optimization problem. The optimization algorithm OptTopo achieves efficient set-points by traversing a graph representation of the overall system. © 2022, CC BY.

关键词： Optimization

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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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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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Oxidized tool electrodes for optimized electro-discharge drilling 20

Oxidized tool electrodes for optimized electro-discharge dri...

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

作者： Uhlmann, E. Polte, M. Streckenbach, J. Dinh, N.C. Börnstein, J. Wolf, C.-S. Camin, B. Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Materials Science and Technology Chair of Metallic Materials Technische Universität Berlin Germany

ISBN: (纸本)9780995775176

The production of components for automotive and aerospace industry by conventional machining is still limited by hardness and strength of the workpiece materials. Electro-discharge drilling is used for machining electrically conductive materials without any limitation due to mechanical properties. Electro-discharge drilling causes debris in the working gap, which leads to arcs and short circuits on the lateral surface with negative effects on processing results and process duration. Due to these arcs and short circuits limited drilling depth, increased tool wear, conicity of boreholes and process instabilities are still challenges in electro-discharge drilling. In this work, a new approach for passivation of the tool electrode material by oxidation is shown. Different oxidation processes for tool electrodes made of brass were applied and analysed. Surface modified tool electrodes were used for electro-discharge drilling of Elmax, SuperClean from the company VOELSTAPINE AG, Linz, Austria. The investigation was carried out on the machine tool AGIETRON Compact 1 from the company AGIE SA, Losone, Switzerland, for machining of through holes with a depth of t = 33.5 mm using different surface modified tool electrodes with a diameter of d = 0.8 mm. First results show a reduction of the erosion duration by 20 % for the application of thermally oxidized brass. The investigation of different defined oxide layer thicknesses and electrical resistances for specific applications are part of this ongoing work. This work is funded by the German Research Foundation (DFG). Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Oxidation

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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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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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A Comprehensive Investigation on Microstructure and Mechanical Properties Optimizing of 316l Stainless Steel Produced by Laser-Based Powder Bed Fusion

SSRN

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SSRN 2023年

作者： Farabi, Ehsan Khorasani, Mahyar Mirzaei, Ahmad Ghasemi, Amir Hossein Littlefair, Guy Macdonald, Eric Leary, Martin Gibson, Ian Rolf, Bernard Institute for Frontier Materials Deakin University Waurn PondsVIC Australia Centre for Additive Manufacturing Royal Melbourne Institute of Technology MelbourneVIC Australia Faculty of Engineering University of Texas El Paso United States Australian Institute of Science & Technology NSW Australia Faculty of Design and Creative Technologies Auckland University of Technology New Zealand Fraunhofer Centre for Complex System Engineering Department of Design Production & Management University of Twente Netherlands School of Engineering Deakin University Waurn PondsVIC Australia

The laser-based power-bed fusion (LB-PBF) additive manufacturing (AM) has become a forefront of AM technologies to produce 316L stainless steels with superior mechanical and corrosion properties compared to conventional methods. However, there is a lack of understanding of the effective manufacturing window which can introduce optimum energy consumption, characteristic microstructure, and properties. As such, this study aims to identify the role of different LB-PBF process parameters (i.e., laser power, scan speed, hatch space, and laser-pattern angle) and different post-heat treatment procedures to obtain enhanced mechanical properties in of 316L stainless steel with limited optimal energy usage. To this end, Taguchi’s design of the experiment (DoE) was elaborated to define the ideal LB-PBF process and heat treatment parameters. Based on the DoE and experimental results, the LB-PBF energy density between 6.7 J/mm3 to 14.7 J/mm3 produced parts with a volumetric mass density of 98.8% or higher. The parts manufactured with laser power of 175 W and heat treated at 870 °C for 2 hours were shown to present the highest tensile strength of ~970 MPa and elongation up to ~40%. The microstructure results show that the change in the process parameters leads to grain size, texture and boundary characteristics variations. The heat treatment at 650, 870, and 1150 °C results in grain reorientation from to components and preferential grain growth up to ~45 μm. It was found that dislocation and grain boundary strengthening played a significant role in enhancing the mechanical properties of the as-built material. While the growth of grains during the heat treatment procedure increased mechanical twinning propensity and dynamic Hall-Petch effect, further improving the strength and ductility of the material. © 2023, The Authors. All rights reserved.

关键词： Austenitic stainless steel

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Harmonization of Heterogeneous Asset Administration Shells

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Procedia CIRP 2022年 107卷 95-100页

作者： Nikolaos-Stefanos Koutrakis Varun Gowtham Wenzel Baron Pilar von Pilchau Thomas Josef Jung Julian Polte Jörg Hähner Marius-Iulian Corici Thomas Magedanz Eckart Uhlmann Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer FOKUS Kaiserin-Augusta-Allee 31 10589 Berlin Germany University of Augsburg Am Technologiezentrum 8 86159 Augsburg Germany Robert Bosch GmbH Robert-Bosch-Campus 1 71272 Renningen Germany Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Pascalstr. 8-9 10587 Berlin Germany

In the era of digital transformation of the manufacturing and process industry, heterogeneity of assets is one of the most challenging issues towards digitally integrating components within the Industrial Internet of Things. In this context every participant relies on its proprietary digitalization approach envisioned by Plattform Industrie 4.0. To consolidate these heterogeneous data exchange interfaces, e.g. communication protocols, data formats etc., an intermediate step of harmonization is required. Our contribution provides an architecture based on the Asset Administration Shell standard to bring heterogeneous Cyber-Physical-systems together. We illustrate the functionality through an abstract use-case.

关键词： Asset Administration Shell Digital Twin Virtual Sensor Sensor Networks IIoT I4.0 MQTT OPC UA

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Simulation of metal cutting with cutting fluid using the Finite-Pointset-Method

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Procedia CIRP 2021年 101卷 98-101页

作者： Eckart Uhlmann Enrico Barth Tobias Seifarth Maximilian Höchel Jörg Kuhnert Almut Eisenträger Institute for Machine Tools and Factory Management (IWF) Technische Universität Berlin Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Industrial Mathematics ITWM Fraunhofer-Platz 1 67663 Kaiserslautern Germany

Despite the common use of cutting fluids in metal cutting, most simulations of these processes only consider dry conditions. This is largely due to limitations in conventional simulation methods, such as the Finite Element Method (FEM), regarding fast changing computational domains. In this paper, a simulation model of metal cutting with cutting fluid based on the Finite Pointset Method (FPM) is presented. This approach allows to simulate the Fluid-Structure-Interactions (FSI) within the same simulation method. For different orthogonal turning processes, the simulations are compared with experiments for dry and wet conditions. The simulation results illustrate the cooling effect numerically.

关键词： Simulation Fluid Turning

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