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33rd CIRP design Conference

作者： Mügge, Janine Hahn, Inka Rebekka Riedelsheimer, Theresa Chatzis, Johannes Boes, Joachim Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany TEC4U-Ingenieurgesellschaft MbH Saar-Lor-Lux-Straße 15 Saarbrücken66115 Germany

With the EU Green Deal and the UN Sustainable Developments Goals, the vision of a greenhouse gas-neutral and resource-efficient economy is already firmly anchored in world politics. In this context, the automotive industry faces many challenges including the increasing scarcity of natural resources, a rising demand in terms of sustainable vehicle design, production and materials sourcing. Due to all this, end-of-life decisions regarding dismantling have become increasingly important. A high proportion of secondary materials will be required in the vehicles of the future. To response to these challenges, companies have turned their focus towards the circular economy as a central approach to close material loops. In the German research project "Catena-X" a new data ecosystem with digital twins is one enabler that is being developed. The digital twins represent a promising approach to the circular economy by ensuring transparent, product-specific and end-to-end data exchange throughout the entire product lifecycle, from the material sourcing to the eventual dismantling and recycling. As one particular and unique solution, a decision framework that facilitates the best circular strategy at the end of a vehicle's life is developed and presented in this paper. The underlying data-driven decision support framework is based on circular economy KPIs. This includes material, components and specific vehicle KPIs to best identify the most suitable circular strategy. The framework was methodologically developed by an interdisciplinary team of partners, who are stakeholders throughout the value chain and participants in the Catena-X project. An integrated approach of user-centered design, an adapted version of the V-model and the Scaled Agile Framework were used for the methodology in the development of the solution. The paper presents the concept of a digital twin for a decision support system, that includes a central decision logic that also includes the relevant KPIs and a sur

关键词： Sustainable development

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

Micro-texture dependent temperature distribution of CVD diam...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Uhlmann, E. Schröter, D. Gärtner, E. Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute For Production Systems And Design Technology Ipk Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute For Machine Tools And Forming Technology Iwu Reichenhainer Str. 88 Chemnitz09126 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 ΔÏ't = 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 ΔÏ'T = 24.7 % was possible. © 2022 The Authors.

关键词： Turning

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Innovative measurement of stress superposed steel strip for straightening machines 24

Innovative measurement of stress superposed steel strip for ...

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24th International ESAFORM Conference on Material Forming, ESAFORM 2021

作者： Bader, Fabian Bathelt, Lukas Djakow, Eugen Homberg, Werner Henke, Christian Trächtler, Ansgar Department of Forming and Machining Technology Paderborn University Germany Fraunhofer Institute for Mehatronic Systems Design Germany

ISBN: (纸本)9782870193020

Higher quality requirements by customers demand higher precision and accuracy from manufacturing processes. Application oriented preparation of semi-finished materials is key for subsequent forming operations, therefore, straightening machines are employed. Straightening strengthens the material by increasing plastic deformation by means of strain hardening, resulting in undesirable reduction in formability when processing high strength materials, in particular. Conventional roll-type straightening machines process either bars or strips. This is achieved upon passing material between rolls arranged in two staggered rows. However, conventional straightening processes do not adapt to the local varying distortion of coiled strips. Innovative, self-correcting process control techniques, which adapt to the initial geometric characteristics of the strip, present a promising approach to fix this issue through optimization of the leveling process. Here, an innovative strategy to improve straightening of high strength steel materials (1.4310) is presented. This implements optimized leveling, adding minimal plastic deformation and, thus, strain hardening. To operate an intelligent straightening machine, a reliable online measurement of the surface defects is fundamentally essential. The MagnaTest, which is developed for material testing, is made feasible for such purposes after calibrating for curvature measurement. Preliminary results are promising in regards to measuring the curvature online, so that the following straightening process can be close loop controlled. The bending measurement is linked to open/closed loop control, therefore providing an optimal straightening result in regards to formability, leveling, and reduced strain hardening. © ESAFORM 2021 - 24th Inter. Conf. on Mat. Forming. All rights reserved.

关键词： Strain hardening

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

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Procedia CIRP 2024年 122卷 1018-1023页

作者： Janine Mügge Anne Seegrün Lynn Faßbender Theresa Riedelsheimer Philip Staufenbiel Kai Lindow Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany LRP-Autorecycling Leipzig GmbH Priesterstraße 6 04509 Krostitz 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.

关键词： Circular Economy Sustainability Life Cycle Assessment Data Flow Decision Support

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Fundamental study on embedded displacement sensor arrays for ultrasonic-assisted ultraprecision machining 22

Fundamental study on embedded displacement sensor arrays for...

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

作者： Uhlmann, E. Polte, M. Bulla, B. Dambon, O. Dicke, C. Hocke, T. Thißen, K. Heper, M. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Son-x GmbH Aachen Germany

ISBN: (纸本)9781998999118

Ultraprecision machining is a key technology for manufacturing complex steel moulds with dimensional accuracies in sub-micrometer range for mass production of optical components using micro-injection moulding. According to the state of the art, during the machining of carbide-forming metals, such as steel alloys, used single crystal diamond tools suffer from excessive tool wear. In order to overcome this technological und economical limitation, ultrasonic-assisted ultraprecision machining is applied successfully in a broad range of industrial and scientifically applications. Based on the reduction of the contact time between the tool and the workpiece excessive chemical and related tribological tool wear can be avoided. Nevertheless, the cutting speed is strictly limited to deceed critical contact times. Therefore, the monitoring of the tool vibration characteristic and thus the process control is a major challenge and of current industrial and scientifically interest. To overcome these challenges a method for in-situ measurement of the ultrasonic vibration is currently being developed and first results are shown. Using the sophisticated ultrasonic system, developed by SON-X GMBH, Aachen, Germany, up to a frequency fUS= 100 kHz the application of a dedicated eddy current sensor enabled the determination of the real path lines and the exact position of the cutting edge during the whole process with a displacement amplitude AD= 1 µm. The results were subsequently verified by laser vibrometer measurements. As a result of the investigation, an elliptical path movement of the cutting edge in the longitude direction AD,y= ± 1.0 µm and in z-direction AD,z= ± 0.34 µm could be determined using a frequency fUS= 100 kHz. Based on this new measurement method, the vibration characteristic can be specifically varied and adapted to the application. In addition, a comprehensive scientifical knowledge of the process can be gained and used to improve tool wear models. © European Soci

关键词： Vibration analysis

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Towards High-Payload Admittance Control for Manual Guidance with Environmental Contact

arXiv

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arXiv 2022年

作者： Haninger, Kevin Radke, Marcel Vick, Axel Krüger, Jörg The Department of Automation The Fraunhofer Institute for Production Systems and Design Technology Germany

Force control enables hands-on teaching and physical collaboration, with the potential to improve ergonomics and flexibility of automation. Established methods for the design of compliance, impedance control, and collision response can achieve free-space stability and acceptable peak contact force on lightweight, lower payload robots. Scaling collaboration to higher payloads can allow new applications, but introduces challenges due to the more significant payload dynamics and the use of higher-payload industrial robots. To achieve high-payload manual guidance with contact, this paper proposes and validates new mechatronic design methods: standard admittance control is extended with damping feedback, compliant structures are integrated to the environment, and a contact response method which allows continuous admittance control is proposed. These methods are compared with respect to free-space stability, contact stability, and peak contact force. The resulting methods are then applied to realize two contact-rich tasks on a 16 kg payload (peg in hole and slot assembly) and free-space co-manipulation of a 50 kg payload. © 2022, CC BY.

关键词： Industrial robots

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A Filter Calibration Method for Laser-Scanned Weld Toe Geometries

SSRN

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SSRN 2024年

作者： Renken, Finn Jung, Matthias Ehlers, Sören Braun, Moritz Institute for Ship Structural Design and Analysis Hamburg University of Technology Hamburg Germany Fraunhofer Institute for Mechanics of Materials IWM Freiburg Germany Institute of Maritime Energy Systems Geesthacht Germany

Scanned weld seams enable evaluation of local weld toe geometry for fatigue assessments. Laser scanned profiles, though, often contain noise, necessitating data filtering, which can impact results significantly. A calibration of filter parameters is crucial. This study presents a calibration method for filtered laser-scanned weld profiles using artificial weld geometries. Optimization methods adjust different filter functions on predefined weld toes with artificial noise. The resulting data is validated on real specimens. Satisfactory results were obtained with precisely set filter input parameters. Gaussian and Lowpass filters emerge as the most suitable, being universally applicable. To assess radii and angles, a tolerance range is introduced defined by the theoretically minimum measurable radii and angles. Using an adjusted Lowpass filter and a 0.07 mm point distance, a radius measurement within a 0.2 mm and an angle measurement within a 1.5° tolerance range is achievable for the majority of measurements. © 2024, The Authors. All rights reserved.

关键词： Geometry

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Conceptual Approach for a Digital Value Creation Chain Within the Timber Construction Industry – Potentials and Requirements 18th

Conceptual Approach for a Digital Value Creation Chain Withi...

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18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Schramm, N. Oertwig, N. Kohl, H. Chair of Sustainable Corporate Management Technische Universität Berlin Straße des 17. Juni 135 Berlin10623 Germany Fraunhofer-Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany

ISBN: (纸本)9783031288388

This paper addresses the megatrend of urbanization as well as the associated challenges of climate change and its relation to sustainable manufacturing. An enormous lever for improving the climate balance is offered by the consistent use of renewable building materials. In the Berlin/Brandenburg metropolitan region, wood as a building material in particular should play a central role in achieving the climate targets. To realize this, it is not only necessary to use the potential of wood as a raw material for storing carbon, but also to embed wood construction in regional value chains and integrated digital production systems in order to be able to optimally design innovative value creation fields, new regional products and efficient material cycles for increasing sustainability. In the context of this work, the information flows along the value chain are investigated and transferred into a digital model. Existing digital concepts such as the "Open BIM" approach (Building Information Modeling) have been incorporated and shape the entirety of the value chain module developed in this paper for serial prefabrication in multi-story timber construction. Material and information flows are analyzed, interfaces between the actors are identified, value-adding factors of timber system construction are systematically examined for their effects, and industrial prefabrication is aligned with a digital model. © 2023, The Author(s).

关键词： Wooden construction

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Novel Advances in Machine Tools, Tool Electrodes and Processes for High-Performance and High-Precision EDM 15

Novel Advances in Machine Tools, Tool Electrodes and Process...

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15th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2021

作者： Uhlmann, Eckart Polte, Mitchel Yabroudi, Sami Technische Universität Berlin Institute for Machine Tools and Factory Management Pascalstrasse 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstrasse 8-9 Berlin10587 Germany

High-performance electrical discharge machining (EDM) is a key technology for manufacturing high-precision components in a broad range of industrially relevant applications. Formation of debris in the working gap leads to arcing and short-circuits on the surface as well as related inaccuracies and process instabilities. Despite decades of research in the field of EDM excessive tool wear and limited process performance are still challenging. In order to overcome highly complex state-of-the-art challenges, dedicated processes, machine tools, peripheral systems, software, tool electrodes and technologies for the application of alternative dielectric fluids have been developed. Within this work novel advances in the development of a sophisticated dry EDM machine tool, including generator and process control technology based on open architecture, open source software, and commonly available machine tool components, are presented. Solutions for challenges regarding remaining debris and gas bubbles as well as related arc discharge and short-circuit pulses in sinking EDM are presented by new flushing methods, technologies and devices. A new system for inverted pressure flushing of a dielectric fluid in ED-drilling enables a highly efficient removal of debris and gas bubbles through the interior channels of the tool electrode. A new multi-luidic spindle system for EDM provides the ability to use performance- and material-related application of gaseous, near-dry and liquid dielectric fluids sequentially within a single machining process. Recent advances in tool electrode design, tool electrode material application, modification and production have led to essential process improvements. A helical tool electrode design significantly improved flushing conditions and related material removal rate in ED-drilling. Modification of ED-drilling tool electrode surfaces by thermal oxidation of copper reveals a promising approach to minimize ineffective discharges. Application of a speci

关键词： Debris

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Impact of illumination technique on the detectability of irregularities in high-resolution images of visual in-situ process monitoring in Laser Powder Bed Fusion 13

Impact of illumination technique on the detectability of irr...

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13th CIRP Conference on Photonic Technologies, LANE 2024

作者： Merz, Benjamin Schmidt, Jonathan Poka, Konstantin Mohr, Gunther Polte, Julian Hilgenberg, Kai Bundesanstalt für Materialforschung Und-prüfung Unter den Eichen 87 Berlin12205 Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany

The layerwise geometry build-up of additive manufacturing (AM) enables the possibility of in-situ process monitoring. The objective is the detection of irregularities during the build cycle, ensuring component quality and process stability. Focus of this work is the visual in-situ monitoring of the process of powder bed fusion with laser beam of metals (PBF-LB/M). Current state of the art visual monitoring systems for PBF-LB/M are limited by low resolution, allowing the detection of gross flaws. In this work a 65 Mpixel high-resolution monochrome camera is integrated into a commercial PBF-LB/M machine enabling a spatial resolution of approx. 17.2 μm/Pixel. The observed inhomogeneities are clustered into directly detectable irregularities, and indirectly detectable irregularities that can be inferred from the surface. In parallel, two different illumination techniques are realized in the process chamber and compared. The impact of the distinct illumination technique, direct light and dark field, on the identification of irregularities is evaluated. © 2024 The Authors.

关键词： Laser beams

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