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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Polte, M. Hocke, T. Felder, F. 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)9781998999132

In order to meet the continuously increasing function-determining requirements of complex precision components, advances in machine tool components are necessary in addition to technological developments. In this context, motorized spindles in particular show great potential for enabling further increases in accuracy. To achieve high stiffness and damping behaviour of spindle systems, aerostatic bearings made of graphite with bearing gaps Sg S ≤ 1 μm are necessary. Regarding the state of the art, uncoated tungsten carbide tools, diamond coated carbide tools and thick film chemical vapour deposition (CVD) diamonds are used for cutting graphite materials. Cutting with these tools leads to asymmetric breakout behaviour of the graphite grains as well as high tool wear during machining, resulting in insufficient shape accuracies and surface qualities. A promising approach to overcome the current challenges for aerostatic bearing components made of graphite is the use of single crystal diamonds (SCD) with characteristic low rounded cutting edge radii rß ≤ 20 nm as well as cutting-edge waviness wa ≤ 200 nm. Besides the material-specific properties of the SCD, tool wear occurs during the cutting of graphite. For this purpose, the abrasive wear mechanism and surface attrition of SCD were analysed concerning specific blasting tests with defined time intervals of 60 s ≤ tb ≤ 3,000 s and different process conditions. Furthermore, two types of graphite granulate with grain sizes in a range of 200 μm ≤ gs ≤ 400 μm were used. First results show a dimensional loss of material on the investigated specimens made of SCD depending on the process conditions, whereby an influence of the surface attrition could be proven. © 2023 Euspen Headquarters.

关键词： Graphite

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DEM simulation of centrifugal disc finishing using smoothed particle hydrodynamics 23

DEM simulation of centrifugal disc finishing using smoothed ...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Polte, J. Kuche, Y. Hocke, T. 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)9781998999132

Centrifugal disc finishing is a widely used technology forserial post-processing of small components made of various materials. During the process, the workpieces are completely surrounded by dry or moist abrasive media, making it difficult to obtain precise information about particle contacts or the movement of the workpieces. Numerical analysis through the discrete element method (DEM) has the potential to improve the understanding of the process, but the accurate representation of moist particles with varying contact conditions remains a challenge. This paper compares different contact models using the ROCKY DEM software, including the liquid-bridge model and the smoothed particle hydrodynamics (SPH) model. The analysis indicates that, compared to other models, SPH demonstrates clear advantages in representing process water flow and is better suited for cases with higher water content in the medium. © 2023 Euspen Headquarters.

关键词： Finite difference method

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DEM Simulation of Abrasive Brushing Processes on Additively Manufactured Workpieces 20

DEM Simulation of Abrasive Brushing Processes on Additively ...

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20th CIRP Conference on Modeling of Machining Operations in Mons, CIRP CMMO 2025

作者： Hoyer, Anton Uhlmann, Eckart Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

Brushing with bonded abrasives is a finishing process mainly used for deburring, edge rounding, and surface roughness reduction. The brushing tools consist of flexible polymer filaments embedded with abrasive grains, allowing them to adapt to complex workpiece shapes. However, interactions between filaments lead to complex motion, chipping, and wear behaviors, making it difficult to predict work results. The discrete element method (DEM) has been shown to be effective in simulating process forces, contact areas, and filament interactions on flat workpieces. Consequently, this article focuses on processing geometrically complex workpieces, particularly additively manufactured turbine fan blades (Ni-Cr-Co), using round brushes with bonded silicon carbide. First, a vectorized iterative method is introduced to generate artificial filament patterns, enhancing DEM simulation accuracy compared to state-of-the-art filament pattern models. Subsequently, dry brushing experiments are carried out on a fan blade feature demonstrator, aiming to achieve homogeneous roughness reduction. The qualitative analysis of the contact surface suggests that results from DEM simulations can reduce the need for costly technological investigations and prototypes. © 2025 The Author(s).

关键词： Nickel alloys

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technology Radar for a Sustainable Biological Transformation in the Manufacturing Industry 19th

Technology Radar for a Sustainable Biological Transformation...

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19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Mügge, Janine Berkhahn, Magda Knauf, Tobias Stark, Rainer Faßbender, Lynn Lange, Annika Riedelsheimer, Theresa Lindow, Kai Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

ISBN: (纸本)9783031774287

Bio-inspired, bio-integrated, bio-intelligent product and production systems are new research approaches aimed at achieving sustainability in manufacturing. For the industrial application of new technological solutions, it is crucial to convey their added value from not only an economic but also an environmental perspective. The evaluation of their technological readiness plays an important role in implementation. This paper presents a technology radar developed and evaluated within German research project BioFusion 4.0 involving 13 industry and research partners. The paper outlines the development approach and its application by means of three technological examples. The technologies are categorized and assessed using four significant attributes of an effective biological transformation: (1) the mode of action (bio-inspiration, bio-integration, and bio-interaction);(2) the transformative character and (3), the technology—and (4) Sustainability Readiness Level. The technology radar comprises a step-by-step procedure to assess a technology by each criterion to enable different stakeholders, such as production planners or product developers to evaluate and identify suitable technologies according to their needs and business strategy. The application of the technology radar is demonstrated on the exemplary technologies of a digital twin with integrated life-cycle assessment, situation awareness monitor for networked production systems and bio-based 3D printing. © The Author(s) 2025.

关键词： Biotic

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Corporate Climate Protection Measures to Improve the Carbon Footprint in production: A systematic Development of a Toolbox with Climate Protection Actions for the Reduction of Greenhouse Gas Emissions in Small and Medium-Sized Enterprises 19th

Corporate Climate Protection Measures to Improve the Carbon ...

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19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Budde, Felix Kohl, Holger Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

ISBN: (纸本)9783031774287

Individual climate protection measures are already being successfully implemented by many companies. But often, there is a lack of comprehensive information for selecting and implementing the right measures that fit the individual company’s emissions profile. This paper presents the systematic development of a toolbox of climate protection actions for small and medium-sized enterprises in order to reduce greenhouse gas emissions. The development process followed a four-step methodological approach: conducting intensive research on climate protection measures in applied and practical literature, reducing and grouping the measures into their corresponding emission categories, structuring and categorizing the measures into specific types of areas, and providing detailed profiles and descriptions of each measure. The resulting list of climate protection actions follows underlying basic principles (i.e. improvement of the emission factor, reduction of emission-generating activities and behavioral changes) which allow an individual derivation of measures. In its final version, the toolbox provides small and medium-sized enterprises with a comprehensive and accessible resource for identifying and implementing effective climate protection actions according to their emissions profile. © The Author(s) 2025.

关键词： Greenhouse gas emissions

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Planning of Time-Efficient Trajectories for Mobile Robots with Differential-Drives

Planning of Time-Efficient Trajectories for Mobile Robots wi...

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International Conference on Emerging Technologies and Factory Automation (ETFA)

作者： Philipp Lelidis Axel Vick Production Machinery and Equipment Management Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Process Automation and Robotics Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany

ISBN: (数字)9798350361230

ISBN: (纸本)9798350361247

To effectively utilize the capacities of the production facilities, flexible and fast transport, and manipulation technology is essential. Current path planning methods use simple paths without exploiting the physical limitations of mobile robots. This paper deals with the time-efficient kinematic planning of path and velocity trajectories for autonomous mobile robots equipped with a differential-drive, used to load and unload machine tools. For a close parking position next to the machine tools, the mobile robot must approach practically straight without the necessity of turning at the end. After a brief definition of the kinematics of a mobile robot with nonholonomic constraints, a Bezier-curve is combined with multiple jerk-limited velocity trajectories considering the initial and final state as well as the physical limitations. For a time-efficient acceleration and deceleration the maximum acceleration of the mobile robot is used and differentiated into the radial and tangential acceleration. This allows a quickly reached close parking pose next to a machine tool. The algorithm is tested with simulations in RVIZ in combination with Gazebo and ROS2 as well as with the real mobile robot Tend-o-Bot.

关键词： Kinematics Turning production facilities Trajectory Planning Machine tools Mobile robots Manufacturing automation Load modeling Autonomous robots

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Enabling digitally integrated product design and production through digital continuity and feedback to design

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Procedia CIRP 2024年 128卷 627-632页

作者： Tschiltschke Till Manoury Marvin Michael Riedelsheimer Theresa Lindow Kai Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany

Due to global and political influence, resilient and versatile production systems are unavoidable. Based on existing Product Lifecycle Management (PLM) systems there is a growing need for a consistent communication between machines and product design to enable integrated product and production process design. Core aspects are integrating the product design information directly into the production equipment and their feedback into the product design as well as into other phases of the product creation and usage. Therefore, a generalized production description language as well as an architecture for the digital integrated product design and production need to be developed. This paper presents the first results of a use case in the automotive industry. The approach of developing the functional architecture is shown. Several feedback to X approaches were researched in literature and analyzed regarding functional requirements for integration in the developed architecture. The results are the main basis for further implementation within the automotive production. Moreover, the main challenges and next steps are discussed.

关键词： product production system architecture production description language design methodology tools technologies

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Developing Digital Twins for energy efficiency in the production phase of products

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Procedia CIRP 2024年 122卷 933-938页

作者： Sebastian Wehking Theresa Riedelsheimer Cansu Tanrikulu Kai Lindow Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany

The relevance of digital solutions to enable sustainable value creation, the monitoring and ultimately the reduction of the environmental footprint has increased. New information technologies and increased data availability along a product's lifecycle offer more tools to assess product sustainability than ever before. This paper presents how a Digital Twin needs to be designed to help monitor product-level energy efficiency and how such a Digital Twin can be implemented. State-of-the-art research on Digital Twins and their development, lifecycle assessment, and energy efficiency are introduced. There is a lack of evaluated implementations of methodical DT development in different scenarios, especially for the evaluation of product-level energy efficiency during production. Results of a research project with the focus on the development and implementation of Digital Twins are presented. The use case is set within the scenario of the sequential development of a product simultaneously with the development of the Digital Twin. The focus is put on the implementation of an energy consumption prediction and product carbon footprint analytics module as part of the Digital Twin. The development approach is presented and recommendations for the development of future Digital Twins are derived.

关键词： Digital Twins Sustainability Lifecycle Assessment Energy efficiency

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Sustainable Product Lifecycle Management – Implementation of a Digital Twin of a Biologically Transformed Product-Ecosystem

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Procedia CIRP 2024年 125卷 30-35页

作者： Sebastian Wehking Anne Seegrün Theresa Riedelsheimer Kai Lindow Fraunhofer-Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany

Biological transformation is the transfer of principles of natural systems to technical materials, processes and systems. The essential concepts of biological transformation - inspiration (learning from the observation of nature for the adaptation of technology), integration (symbiosis of technical systems based on biological principles) and interaction (interweaving of nature with technology) - can be transferred to Industry 4.0 solutions. One of these solutions is the Digital Twin, which can be used to provide transparency of an individual product’s environmental impact and to positively influence it throughout all lifecycle phases. A Digital Twin can be seen a digital ecosystem that inherits various biological principles itself, but also serves as an enabler of biologically transformed products. The application of the principles of biological transformation to Industry 4.0 helps achieve sustainable value creation. Manufacturing and operating companies, leveraging operational data with the help of Digital Twins, are equipped to better understand a product ecosystem’s performance and identify constraining resources that determine its lifecycle sustainability. This paper demonstrates the concept development of a Digital Twin for a biologically transformed product-ecosystem with integrated sustainability assessment focused on the production phase and its corresponding user interface.

关键词： Biologicalisation Industry 4.0 Biological Transformation Sustainability Sustainable Manufacturing Digital Twin

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Integrated Consideration of Data Flows and Life Cycle Assessment in Vehicle Dismantling processes 31

Integrated Consideration of Data Flows and Life Cycle Assess...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Mügge, Janine Seegrün, Anne Faßbender, Lynn Riedelsheimer, Theresa Staufenbiel, Philip Lindow, Kai Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany LRP-Autorecycling Leipzig GmbH Priesterstraße 6 Krostitz04509 Germany

The pursuit of environmental sustainability and resource conservation has underscored the growing significance of the circular economy paradigm across industries. This transformation is particularly pertinent within the automotive industry, necessitating a profound restructuring of the value chain, with a specific focus on end-of-life considerations. Significant potential for circular economy arises from the thorough examination of end-of-life vehicles and processes, involving strategies such as component reuse, material recycling and primary resource reduction. Providing process-, product-, component-, and material-specific information at the end-of-life of automotive vehicles can improve decision-making regarding circular strategies. It also demands for new digital solutions. This paper addresses an integrated approach of data flow analysis and Life Cycle Assessment (LCA) to enable a comprehensive monitoring of the environmental impact of these processes. First, the use case of end-of-life dismantling processes is presented - including pyrotechnics neutralization, vehicle dehydration, disassembly of reuse components as well as vehicle compaction. Secondly, the data demand respective information and material flows is depicted. As a main result, the LCA data flow model specifically tailored to the end-of-life vehicle dismantling processes is described. This model serves as a fundamental basis for analyzing the environmental impact of end-of-life processes combined with the underlying data flow. © 2024 Elsevier B.V.. All rights reserved.

关键词： Life cycle

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