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PRECISION FINISHING OF ADDITIVE MANUFACTURED Ti-AI-COMPONENTS USING DIAMOND SLIDE BURNISHING

PRECISION FINISHING OF ADDITIVE MANUFACTURED Ti-AI-COMPONENT...

引用

2022 ASPE and euspen Summer Topical Meeting on Advancing Precision in Additive Manufacturing

作者： Polte, Julian Polte, Mitchel Lahoda, Christian Uhlmann, Eckart Fraunhofer Institute for Production Systems and Design Technology IPK Technische Universitat Berlin Berlin Germany Institute for Machine Tools and Factory Management IWF Technische Universitat Berlin Berlin Germany

ISBN: (纸本)9781713859192

Due to the increasing importance of lightweight design in terms of resource management, titanium aluminium (Ti-AI) alloys are gaining more and more significance. To fully exploit light weight design potentials additive manufacturing (AM) has the ability to shift state of the art product design towards maximised resource efficiency and physically minimized weight. Next to material standardization and qualification processes, major limitations for mass scale industrialization of additive manufacturing are high surface roughness values in a range of 5 μm ≤ Ra ≤ 15 urn and remaining tensile residual stress states. A promising approach to overcome these challenges shows a process chain consisting of near-net-shape laser powder bed fusion (LPBF) and subsequent finishing using a dedicate diamond slide burnishing (DSB) process [1]. Within this work plastic deformation induced by DSB and the effects on the workpiece material properties were investigated. Copyright© (2022) by American Society for Precision Engineering (ASPE) All rights reserved.

关键词： Surface roughness

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Influence of superimposed low frequency oscillations on single-pass honing of long-chipping steel 6th

Influence of superimposed low frequency oscillations on sing...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Uhlmann, E. Rozek, A. Pascalstraße 8-9 Berlin10587 Germany Fraunhofer Institute For Production Systems And Design Technology Ipk Pascalstr. 8-9 Berlin10587 Germany

Single-pass honing is used as a finishing process to meet high demands regarding form and dimensional accuracy of drilled bores. The disadvantages of single-pass honing compared to the conventional long-stroke honing are high process forces and torques as well as an increased risk of chip space clogging of the abrasive stones. A significant reduction in process forces and torques can be achieved by superimposing the axial movement with oscillations. In this work the kinematic basics of different oscillation parameters and their effects on single-pass honing of long-chipping steel are analyzed. It can be concluded that by superimposing low frequency oscillations in single-pass honing, the process forces and torques as well as the specific energy consumption can be reduced significantly without a decline in surface quality and form accuracy. © 2022 The Authors.

关键词： Honing

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Residual stress assessment during cutting tool lifetime of CVD-diamond coated indexable inserts 6th

Residual stress assessment during cutting tool lifetime of C...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Uhlmann, E. Hinzmann, D. Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute For Production Systems And Design Technology Ipk Pascalstr. 8-9 Berlin10587 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 σR,c shifts to tensile residual stress σR,t underneath the cutting edge corner. The approximated residual stress difference of σR ≈ 5 GPa indicates stress peak relaxation processes, such as crack initiation, within the CVD-diamond coating. © 2022 The Authors.

关键词： Residual stresses

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Experimental investigations of the workpiece-media-interaction and the surface topography formation in centrifugal disc finishing 10

Experimental investigations of the workpiece-media-interacti...

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10th CIRP Global Web Conference on Material Aspects of Manufacturing Processes

作者： Kopp, Marco Uhlmann, Eckart Kneider, Christian Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

In this study the workpiece-media-interaction in centrifugal disc finishing is investigated using a miniaturised free movable force measuring system. Characteristics of the workpiece-media-interaction are derived and correlated with the surface topography formation of Ti-6Al-4V workpieces. As a result, it was found that characteristics of the workpiece-media-interaction such as the contact force between the media and the workpiece, the contact duration and the contact frequency are dependent on the type of media as well as the rotational speed of the disc. Consequently, both, the type of media as well as the rotational speed of the disc have an influence on the resulting surface roughness. © 2022 Elsevier B.V.. All rights reserved.

关键词： Topography

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Process behaviour of segmented and actuated tool electrodes for variable shaping in sinking EDM 22

Process behaviour of segmented and actuated tool electrodes ...

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

作者： Uhlmann, Eckart Thißen, Kai Westhoff, Bela Schulte Streckenbach, Jan Ludwig, Jonas Maas, Jürgen Technische Universität Berlin Institute for Machine Tools and Factuatory Management IWF Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany Technische Universität Berlin Mechatronic Systems Lab EMK Germany

ISBN: (纸本)9781998999118

In sinking electrical discharge machining (S-EDM), many applications such as the manufacturing of injection moulds require numerous tool electrodes due to tool wear compensation. The manufacturing of tool electrodes causes a high cost and time expenditure in the entire process chain. This paper aims for a novel approach to a segmentation of the tool electrode in order to shape it variably. The shaping is realized by actuation of single tool electrode segments (STES) using miniaturized linear actuators. In the future, the roughing process in S-EDM could be carried out by segmenting and variably shaping of the tool electrode. To investigate the process behaviour of a segmented tool electrode in S-EDM, different geometry configurations of the tool electrodes are compared. Experimental results show a similar material removal rate for the different tool electrode configurations. The relative linear wear of a segmented tool electrode is only 7.7 % of the relative linear wear of a monolithic tool electrode. In order to dynamically position the STES, a miniaturized electrical linear drive is developed and constructed. The outer diameter of the actuator must not exceed the edge length of an STES. In the machine tool an actuated STES is tested and the material removal rate and the relative linear wear for different Z-axis lifting motions are analysed. The material removal rate could be increased by 37 % applying actuated Z-axis lifting motions compared to the process without Z-axis lifting motion. In this context the relative linear wear increased slightly. The results of this paper are used for the further development of the system to enable more efficient process chains in the EDM process. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Linear actuators

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Towards Individualized Production with Flexible Shopfloor IT based on Distributed OPC UA Services 13

Towards Individualized Production with Flexible Shopfloor IT...

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13th International DAAAM Baltic Conference and 29th International Baltic Conference, BALTMATTRIB 2021

作者： Wolff, Tobias Vick, Axel Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin Germany

Nowadays, manufacturers face the problems to adjust their production according to the fast-changing global competition. Car manufacturers, for example, are in front of a new era of individual mobility. They need to switch from combustion engines to electric drives. In general, manufacturers have to develop production strategies to lower set up time and meet requirements faster. The classical production line is most effective if the product variety is low and the lot size is high but facing the rapid growing demand for individualized products and fast-changing requirements, manufacturers must discover new ways of manufacturing. One possibility is the flexible shopfloor. In this work, we will present our concept of a flexible shopfloor IT for controlling a robotic demonstrator. We use OPC UA over TSN as a platform for communication and CODESYS as SoftSPS for the control of sensors and actuators. In order to create valid data for ongoing discussions we use function point analysis and counting lines of sourcecode to measure software size. Our expectation is that the initial effort for implementing a flexible shopfloor IT is higher compared to the classic approach, but for all the following implementation it will take less time, because of the possibility of reuse already developed systems. © 2021 DAAAM International. All rights reserved.

关键词： Electric drives

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Residual stresses in additive manufactured precision cemented carbide parts 22

Residual stresses in additive manufactured precision cemente...

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

作者： Polte, J. Polte, M. Hocke, T. Blankenburg, M. Lahoda, C. Uhlmann, E. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Deutsches Elektronen-Synchrotron DESY Germany

ISBN: (纸本)9781998999118

Due to the good strength properties and high hardness, components made of cemented carbide are used in various industrial sectors as key components, e.g. mould making and matrices. Precision cemented carbide parts are mainly machined by milling and electrical discharge machining (EDM). Nevertheless, long machining times and excessive tool wear are remaining challenges at the state of the art. A promising approach to overcome these challenges is the machining of precise cemented carbide parts using a process chain consisting of near-net-shape laser powder bed fusion (LPBF) and subsequent finishing using a dedicate diamond slide burnishing process. Within previous investigations a geometrical accuracy of ag= 10 µm and a reduction of the surface roughness by Ra = 89 % could be achieved. Within this work plastic deformation induced by the diamond slide burnishing and the effects on the material properties in the surface area were investigated, e.g. residual stresses. For this purpose, the lattice distortion of the metallic cobalt phase was measured by X-ray diffraction using high-energy synchrotron radiation. In addition, the height profile of the residual stresses was also recorded in distances of d = 3 µm to obtain information about the depth effect of the diamond slide burnishing process. Based on the investigations an increase of the residual compressive stresses could be obtained. This shows a particularly positive effect especially for additively manufactured components, as these often show a slight porosity and higher surface roughness as conventional manufactured components. In this way, crack propagation can be prevented and the fatigue strength can be increased. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Residual stresses

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Roleplaying made easy – A Meta-model for Roles in systems Engineering

Roleplaying made easy – A Meta-model for Roles in Systems E...

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IEEE International Symposium on systems Engineering (ISSE)

作者： Eva-Maria Grote Daria Wilke Christian Koldewey Roman Dumitrescu IPEK - Institute of Product Engineering at Karlsruhe Institute of Technology Karlsruhe Germany Fraunhofer Institute for Mechatronic Systems Design (IEM) Paderborn Germany Heinz Nixdorf Institute (HNI) Advanced Systems Engineering Paderborn Germany

ISBN: (数字)9798350353723

ISBN: (纸本)9798350353730

Tomorrow’s products and services will be more intelligent, more connected, and more autonomous. Product development is becoming more complex as well; and success will increasingly depend on transdisciplinarity and systems Engineering. Competence and knowledge management are key factors in this evolution. Implementing clear and focused role models is one way of addressing these issues while making organizational structures more flexible. Role models are groups of company-specific role profiles with clearly defined tasks, competences, responsibilities, and authorities. This paper aims to develop a meta-model as the foundation for building role frameworks in systems Engineering. It consists of actors, roles, and organizational tasks that are associated with each other as well as other elements. The meta-model, hence, structures the elements and relationships that must be considered when building a role model.

关键词： Industries Analytical models Face recognition Buildings Collaboration Companies Transforms Knowledge management Product development Complexity theory

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Numerical study on the temperature characteristic of material absorptivity and its significance in high-power laser beam welding 13

Numerical study on the temperature characteristic of materia...

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13th CIRP Conference on Photonic Technologies, LANE 2024

作者： Putra, Stephen Nugraha Meng, Xiangmeng Yang, Fan Bachmann, Marcel Rethmeier, Michael Bundesanstalt for Materialforschung und -Pröfung Unter den Eichen 87 Berlin12205 Germany Technical University 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

The absorptivity of metallic materials plays an important role in high-power laser beam welding. It affects the amount of absorbed laser power leading to the heating and melting of the surfaces to be joined and is highly dependent on the temperature. Nonetheless, this key characteristic is often ignored in numerical simulations and an empirical parameter determined by trial-And-error approaches is rather implemented to calibrate the results. In the present work, the temperature dependence of laser absorption is included in a three-dimensional multiphase numerical model considering the coupled fluid flow and heat transfer. The calculated laser absorption is determined by the temperature-dependent material properties, laser characteristics, and incident angle of the laser beam. It is found that the temperature dependence of the laser absorption is crucial for accurately determining the keyhole and weld pool geometries, which is validated by experimental measurements using 304 austenitic steel. © 2024 The Authors.

关键词： Laser beam welding

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End-of-life decision support to enable circular economy in the automotive industry based on digital twin data 33

End-of-life decision support to enable circular economy in t...

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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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