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Reproducibility analysis for different numerical models and experimental setups in dry orthogonal cutting of AISI 4140 steel 34

Reproducibility analysis for different numerical models and ...

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34th CIRP design Conference, CIRP 2024

作者： Grimm, Christian Menze, Christian Saelzer, Jannis Sauer, Florian Eisseler, Rocco Möhring, Hans-Christian Schulze, Volker Zabel, Andreas Uhlmann, Eckart Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany University of Stuttgart Holzgartenstr. 17 Stuttgart70174 Germany TU Dortmund University Baroper Str. 303 Dortmund44227 Germany Karlsruhe Institute of Technology Kaiserstr. 12 Karlsruhe76131 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

The design of machining processes still requires iterative parameter optimisation on the real process to achieve the demanded quality. In order to use simulation results as input for models of lubricated machining processes, which is the final aim of the presented work, it is necessary to assure that already the chip forming simulations under dry conditions produce valid results. Due to extreme conditions in the chip formation zone, including high contact stresses, temperatures and deformations, advanced requirements are imposed on a numerical model. In this work, orthogonal turning of AISI 4140 steel is simulated and experimentally investigated. Aiming for a critical examination of the conventional practice to validate simulation results only through a single experimental setup, the experiments are carried out redundantly on three varying turning lathes and measurement systems. Numerical simulations are performed using finite element analysis (FEA) within the software packages ABAQUS, AdvantEdge, DEFORM and Marc, as well as meshfree methods in the form of the finite pointset method (FPM) within MESHFREE and an element-free Galerkin method (EFG) in LS-DYNA. The obtained results demonstrate the characteristics of the individual simulation methods as well as the degree of reproducibility in experiments. © 2024 The Authors. Published by Elsevier B.V.

关键词： design informatics Machining Simulation

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Methodology to develop Digital Twins for energy efficient customizable IoT-Products 28

Methodology to develop Digital Twins for energy efficient cu...

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28th CIRP Conference on Life Cycle Engineering, LCE 2021

作者： Riedelsheimer, Theresa Gogineni, Sonika Stark, Rainer Fraunhofer Institute for Production Systems and Design Technology Ipk Berlin Germany Technische Universität Berlin Chair Industrial Information Technology Berlin Germany

Products are increasingly individualized and enhanced to be able to communicate, e.g. via Industrial Internet of Things (IoT). However, the impact of products on sustainability (environmental and social) across their life is often not considered and analyzed. IoT-based or smart products, that are able to communicate, generate data, which can be used to monitor and optimize sustainability indicators. The Digital Twin (DT) is a new technological concept which focuses on product individual data collection and analysis. It provides the possibility to make use of the available data and optimize the systems individual sustainability as well as future product generations. However, the design and realization of such a DT requires new approaches and capabilities, which is an identified research gap. Therefore, this paper presents a methodology to develop DTs of physical IoT-based products, the so called DT V-Model with the aim to optimize the systems sustainability, specifically environmental aspects. It is based on the V-model for the development of smart products and is enhanced with additional roles and approaches for DT development. The methodology is described in detail. The result of a development cycle according to the DT-V-Model is a tested concept of a DT, which includes Digital Master (DM) data from the planning phase and Digital Shadow (DS) data from the production, operation and End of Life-phase. For a DT for energy efficiency, the Digital Master model consists of the information and models from the product development phase including the planned production and use phase energy consumption. The Digital Shadow consists of the actual production energy consumption and the use phase energy consumption. The methodology is applied to a use case of an IoT-based consumer product that can be customized to a certain degree by the consumer. A DT is developed to monitor and optimize the products energy efficiency in production and use. The necessary elements of the DT and t

关键词： Energy utilization

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Simulation and compensation of the thermal behaviour of industrial robots 21

Simulation and compensation of the thermal behaviour of indu...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, J. Mohnke, C. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute of Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Industrial robot systems offer a flexible, adaptable basis due to their kinematics and their mobility. An influencing variable, which is particularly relevant for processes with long process times tP, is the thermal heating and the associated thermal drift ΔAPt of the tool center point. The maximum deviation from the actual nominal position can reach up to ΔAPt = 1.5 mm. In the investigations, a simulation model for an industrial robot was created and the thermal behaviour was mapped. With this model, the thermal error ΔAPt within the working area can be determined as a function of the current position X and temperature ϑ. These data can be used for a targeted correction of the robot path. With the correction by the compensation model the amount of drift for real milling processes could be reduced to a value of ΔAPt = 0.042 mm. The results can help to reduce the influence of thermal heating and the associated thermal drift ΔAPt of the TCP without using cost-intensive measures with additional hardware and software on external computers for compensating the errors. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Error compensation

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Additive manufacturing of precision cemented carbide parts 21

Additive manufacturing of precision cemented carbide parts

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

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

ISBN: (纸本)9780995775190

Cemented carbide parts are commonly used as wear resistance components in a broad range of industry, e.g. for forming, mould making and matrices. At state of the art the machining of precision cemented carbide components by milling is strongly limited due to excessive tool wear and long machining times. Promising approaches for precision machining of cemented carbide components are dedicated cutting tool coatings, new cutting materials like binderless polycrystalline diamond and ultrasonic-assisted machining. Nevertheless, for all these approaches the components need to be machined of monolithic materials. The new approach addresses an innovative manufacturing process chain composed of near net shape Additive Manufacturing followed by a precision finishing process. Within this investigations for the manufacturing of precision cemented carbide parts, cemented carbide with a cobalt content of 17 % and a grain size in a range of 23 µm ≤ gs ≤ 40 µm were used. As Additive Manufacturing technology laser powder bed fusion was used. Diamond slide burnishing and immersed tumbling were investigated as finishing technologies. Based on the investigations, a dedicated process chain for the manufacturing of precision cemented carbide parts could be realised. The findings show that the developed process chain composed of near net shape Additive Manufacturing and the finishing process diamond slide burnishing enables the manufacturing of precision cemented carbide parts with a geometrical accuracy of ag ≤ 10 µm. Due to the finishing process the initial surface roughness after Additive Manufacturing could reduce by Ra = 89 %. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Surface roughness

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Micro-milling of a sprue structure in tungsten carbide-based metal matrix composite 21

Micro-milling of a sprue structure in tungsten carbide-based...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

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

ISBN: (纸本)9780995775190

Many industries rely on plastic components manufactured by micro-injection moulding. There is a high potential to further increase the cost-effectiveness by machining the moulds needed for this process from non-ferrous metals and reinforcing the parts of the mould, which experience high loads during the micro-injection moulding. Inserting tungsten carbide particles locally into the surface of these non-ferrous metals is one possibility of reinforcement. The resulting metal-matrix-composites (MMC) exhibit the needed wear resistance, while the ground material can be machined very effectively through micro-milling. In contrast, the Micro-milling of these MMC-materials is challenging and so far not state of the art. Thus, this investigation is concerned with the development and qualification of micro-milling parameters for tungsten carbide-based MMC-materials. Binderless polycrystalline diamond as innovative cutting material was applied for this purpose. The goal of the milling parameter development was to optimize the surface roughness and the form accuracy for machining an aluminium bronze workpiece reinforced with tungsten carbide particles through laser injection. Based on an analysis of a wide range of process parameters, an optimised milling strategy was applied to machine a sprue structure from the described MMC-material. Different parameter sets are evaluated by analysing the form accuracy and measuring the surface roughness of machined structures. A surface roughness of Ra = 80 nm and form accuracy of a = 3 µm could be achieved with optimized micro-milling parameters and qualified the developed parameters for industrial applications. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Tungsten carbide

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Photocatalytic effect of TiO2-coated surfaces on the pathogenic microorganisms *** and *** 21

Photocatalytic effect of TiO2-coated surfaces on the pathoge...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Hein, C. Brehmer, A. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

The use of titanium dioxide as a strong photocatalytic substance can have a large effect in combating the spread of pathogens through heavily contaminated surfaces. For this purpose, various materials, such as metal, glass, and polymer were coated with rutile- and anatase-rich titanium dioxide by sol-gel method. The contact angle and photocatalytic activity of the coated surface were measured under UV irradiation. The anatase-rich titanium dioxide showed higher photocatalytic activity, which further increased with the coating thickness. The process temperature had an effect on the photocatalytic activity due to the temperature-dependent conversion of anatase to rutile crystal conformation. The coated surfaces had strongly reduced contact angles compared to the uncoated material. In particular, the anatase-rich surfaces resulted in superhydrophilic properties. Photocatalytically induced antibacterial activity against pathogenic microorganisms in liquid environments was demonstrated, especially for gram-negative Escherichia coli bacteria. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Titanium dioxide

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Effects on part density for a highly productive manufacturing of WC-Co via laser powder bed fusion 21

Effects on part density for a highly productive manufacturin...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Polte, J. Neuwald, T. Gordei, A. Kersting, R. Uhlmann, E. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

The additive manufacturing of parts made from difficult-to-weld materials through the usage of preheating temperatures of up to Θ0 ≤ 500 °C is enabled by newest L-PBF machine tools, such as the RenAM 500Q HT from the company RENISHAW PLC, Wottun-under-Edge, UK. This work aims to delevop processing parameters for the dense and crack-free manufacturing of tungsten-carbide cobalt (WC-Co) via this off-the-shelf machine tool. Therefore the laserpower and scanning speed were varied between 80 W ≤ PL ≤ 350 W and 140 mm/s ≤ vS ≤ 650 mm/s respectively. Furthermore the influence of a continuous and pulsed laser mode was analysed. A focus was set on the identification of parameters that enable a highly productive manufacturing while maintaining a high part density. A parameter set for relative density rel. > 94 % and a buildup rate v = 0.59 mm3/s was developed. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： 3D printers

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Cutting edge preparation of monolithic ceramic milling tools 21

Cutting edge preparation of monolithic ceramic milling tools

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, M. Polte, J. Hocke, T. Fraunhofer Institute for Production Systems Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Due to 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 for the machining of brittle materials are in focus to overcome these challenges. One approach to improve the performance and the tool behaviour concerning milling of graphite is the use of monolithic ceramic milling tools. Unfortunately, the high brittleness of the ceramic leads to breakouts on the cutting edge during the grinding process. This results in an increased maximum chipping of the cutting edge, which has a significant influence on the milling process. To improve the breakout behaviour, a cutting edge preparation with the immersed tumbling process was applied. To enable a process reliable cutting edge preparation, a suitable lapping medium, the influence of the processing time as well as the depth of immersion were investigated. Besides the maximum chipping of the cutting edge, the rounded cutting edge radius was also analysed. The results show that a process reliable cutting edge preparation of monolithic ceramic milling tools with a maximum chipping of the cutting edge RS,max ≤ 3 µm and a rounded cutting edge radius of rβ ≤ 7 µm could be realised. In future investigations, the experimental applicability of monolithic ceramic milling tools will be proved. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Brittleness

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Reduction of erosion duration for electrical discharge drilling using a nature analogue algorithm with nested strategy types 21

Reduction of erosion duration for electrical discharge drill...

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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. Osmanovic, 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)9780995775190

The required high economic efficiency, combined with the corresponding high quality demands, in the aerospace industry as well as in mould and tool making, motivate the necessity of finding suitable parameter combinations for the process of electrical discharge machining (EDM), e.g. when introducing new materials. To counteract this, various methods are being investigated in research for the optimisation of EDM. One new method is the stochastic optimisation procedure evolution strategy (ES). Due to its metaheuristic approach, this optimisation method is excellently suited for very complex processes in which the interrelationship of the individual influencing variables is not known. This publication presents the results of the investigation of the suitability of the ES optimisation method using the example of electrical discharge drilling. For this purpose, two nested ES-types were investigated. The electrode materials used were brass for the tool and stainless steel X5CrNi18-1 for the workpiece. As a result, the erosion duration could be reduced by 30 %. This investigation forms the basis for the use of nested ES types in electrical discharge drilling. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Erosion

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Precision finishing of additively manufactured components using the immersed tumbling process 21

Precision finishing of additively manufactured components us...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

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

ISBN: (纸本)9780995775190

Additive manufacturing enables the production of highly complex metallic components with highest geometrical flexibility in dedicated lightweight construction. For titanium-aluminium alloys, which are used in particular in the aviation industry, powder bed based processes such as the laser powder bed fusion are established. Nevertheless, laser powder bed fusion is limited with regard to the producible surface roughness in a range of 5 µm ≤ Ra ≤ 15 µm. According to the state of the art, the increase of the geometrical accuracy and the reduction of the surface roughness values of the additive manufactured components are realised by different cutting and non-conventional processes. In this investigation, a new approach for the reduction of the surface roughness values by immersed tumbling was realised. Therefore, additively manufactured square bars made of the titanium alloy Ti-5Al-5Mo-5V-3Cr were used as sample geometries. An immersed tumbling machine tool with planetary kinematics for post-processing was applied and the lapping media QZ, HSC 1/500 and M5/400 were evaluated. In addition, the influence of the rotor speed and the holder as well as the depth of immersion were considered as influencing factors. As target values the surface roughness values as well as the rounded edge radius were examined. Within this investigations the surface roughness values could be reduced by more than 90 %. In addition, a targeted rounding of the edges could be obtained, which removed the excess edge height at the part resulting from the laser powder bed fusion process. As a result the immersed tumbling process shows a great suitability as a finishing process for additively manufactured components and is particularly suitable for automated and serial finishing processes. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Surface roughness

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