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

作者： Uhlmann, Eckart Trabasso, Luís Gonzaga Bolz, Robert Schweitzer, Luiz Hein, Christoph De Souza, Diego Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany SENAI Innovation Institute for Manufacturing Systems and Laser Processing Brazil

ISBN: (纸本)9781998999132

Tool and mould making is one of the most important sectors of industrial manufacturing. Currently, over a third of polymer products are manufactured by injection moulding or stamping. These processes are complex, as the melted or heated polymers are subject to thermomechanical changes. Since injection moulding and stamping are mostly used for mass production, process repeatability and quality of the final product are very important. Improper adjustments of process variables lead to various defects in the final product along with high amount of waste and rejects. The need for measurement and control of the process is mandatory. Frequently, the tool is not operated by the owner of the mold or the end user of the plastic components, respectively, but by an injection molding service provider within the supply chain. Consequently, it is impossible for the tool owner to trace the quality of parts regarding the parameters applied for processing. This is crucial information to connect parts outside the tolerances to the respective process characteristics. The increase of quality in the production is achievable through correlating the processing parameters applied with the produced components. Therefore, the aim of the research herein is to develop an autonomous sensor system for monitoring injection moulding and stamping processes. The system comprises an external component of the tool in order to record and document the parameters applied such as tool temperature, pressure, number of machined parts and geolocation among others. In conjunction with a connected laser marking system for injection moulding, the unique identification of the components and the unchangeable connection of the production parameters with an individual component is enabled. The direct technological added value is given by the fact that the customer is able to monitor the production at any time, any place, comparing the actual production with the agreed and specified conditions. Furthermore, this info

关键词： Injection molding

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Production environment of toMorrow (ProMo): Partially automated repair process of small tool moulds, forming tools, injection moulding tools and sand casting tools 13

Production environment of toMorrow (ProMo): Partially automa...

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

作者： Kuschan, Jan Müller, Vinzenz Mönchinger, Stephan Heimann, Oliver Niebuhr, Carsten Kabha, Oday Fraunhofer Institute for Production Systems and Design Technology IPK Germany

Small defects in the grain or major damage to a moulded part or tool can bring production to a standstill. SMEs in particular have neither the personnel nor the equipment to repair such damage on their own, so they send it to specialised contractors. The repair process is carried out manually, depending on the accuracy requirements, and is usually completed by a finishing process. This work requires qualified personnel and, at the same time, requires a lot of time in case of larger damages. In this paper we present a way to map the Maintenance, Repair and Operations (MRO) process chain in a partially automated manner. The symbiosis of individual technologies results in a significantly increased efficiency of the MRO process chain, which continues to focus on people and their process knowledge. While Directed Energy Deposition (DED) for the MRO of moulded parts is used widely, usually a high manual effort in measuring the component geometries and teaching of the machine tool paths is necessary. However, there are clear advantages compared to the manufacture of new parts or manual laser welding repair. At the same time, the resource and energy requirements can often be significantly reduced compared to new part production. ProMo focuses on automating the time-consuming machine programming by reducing the number of necessary work steps in CAD/CAM-based program creation. Based on a subsequent robot-guided scan, a digital actual 3D model is generated. Due to intelligent path planning algorithms, no manual programming of the robot is necessary and at the same time it is possible to detect components of different sizes, shapes and covers in this system with a minimum of effort. In addition, the operator passes on elementary information, such as the approach path of the milling head, to the subsequent processes by means of finger gestures and can thus significantly reduce tedious CAM programming steps. Now, the scanned component is transferred to a 3D-CAD model and a target

关键词： Computer aided design

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Surface modification of tungsten carbide cobalt tool electrodes by heat treatment under nitrogen atmosphere for electro-discharge drilling 23

Surface modification of tungsten carbide cobalt tool electro...

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

作者： Uhlmann, E. Camin, B. Polte, J. Polte, M. Streckenbach, J. Dinh, N.C. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Faculty I Materials Engineering Hochschule Bremerhaven Germany

ISBN: (纸本)9781998999132

The requirements for high-precision components for tool and mould-making, automotive and aerospace industries are constantly increasing. Due to the strong mechanical properties of the used materials, such as tool steels and nickel-based alloys, conventional cutting processes are not always suitable. Instead, electrical discharge machining is used for cutting electrically conductive materials. One challenge even today is debris formation, causing arcs and short-circuits in the lateral working gap. This applies particularly to electro-discharge drilling with high aspect ratios and increased difficulties of debris removal. This leads to increased process instability, tool wear and conicity as well as decreased material removal rates. To reduce the effects of arcing and short-circuits in the lateral working gap, tungsten carbide-cobalt tool electrodes with an outer diameter of dO = 1.5 mm were heat-treated to increase the electrical resistivity of the electrode's surface. For this purpose, two different ambient atmospheres were selected, a nitrogen atmosphere and vacuum in comparison. Subsequently, the modified tool electrodes were used to produce boreholes in tool steel of the type Elmax Superclean with a depth of et = 6.75 mm by electrodischarge drilling. The surface modification in the nitrogen atmosphere led to a slightly higher material removal rate and a decrease in the linear tool wear of the tool electrode by up to 6.67 % compared to an untreated reference electrode. © 2023 Euspen Headquarters.

关键词： Heat treatment

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Energy Management for Industrial Robots based on AutomationML

Energy Management for Industrial Robots based on AutomationM...

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International Conference on Control, Decision and Information Technologies (CoDIT)

作者： Valentyn Petrichenko Gregor Thiele Department for Process Automation and Robotics Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany

ISBN: (数字)9798350373974

ISBN: (纸本)9798350373981

Motivated by political regulations and rising energy prices, companies strive for implementing energy management and for reducing their energy consumption. It is an expenditure of work for the energy manager to gather all relevant information about the facilities and machines (e.g. meaning of measurement and control signals, limits of these quantities, installed nominal capacities). In many cases, there is digital planning data from the planning, construction and commissioning phases. Using AutomationML, this information can be used collaboratively not only for engineering and maintenance but for energy monitoring and optimization. In this study, an industrial robot and two conveyors are integrated in the wide-spread energy management software suite EnEffCo. We document the method and results. Implications for deriving optimization formulations are discussed.

关键词： Service robots Industrial robots Software Regulation Planning Maintenance Energy management Information technology Optimization Monitoring

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DEM simulation of centrifugal disc finishing 22

DEM simulation of centrifugal disc finishing

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

作者： Uhlmann, E. Polte, J. Kuche, Y. Landua, F. 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)9781998999118

The finishing of small components with complex geometries is a major industrial challenge. One process that is suitable for targeted post-processing is centrifugal disc finishing with wet and dry media. In this process, the workpieces float as bulk material together with the abrasive particles in a container and are completely surrounded by the abrasive medium. As shown in previous studies, the Discrete Element Method (DEM) is suitable for investigations of grinding processes with specified workpiece motions. To simulate unpredictable workpiece motion, a new approach is being tested in which the workpieces themselves are treated as particles. Within this research paper, results for the post-processing of centrifugal disc finishing with the software ROCKY DEM are presented. The investigation results show good correlation between the numerical determined pressures and the analysis results of the rounded workpiece edges on test components made of mould-steel X13NiMnCuAl4-2-1-1. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Grinding (machining)

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Sustainable product lifecycle management with Digital Twins: A systematic literature review

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Procedia CIRP 2023年 119卷 776-781页

作者： Anne Seegrün Thomas Kruschke Janine Mügge Louis Hardinghaus Tobias Knauf Theresa Riedelsheimer Kai Lindow Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 10587 Berlin Germany

A Digital Twin (DT) is a virtual replica of a product or product-service system, which can be used to provide transparency of a product's sustainability and to positively influence the ecological impact throughout its lifecycle by means of intelligent data analytics. This paper identifies current sustainability-focused application scenarios of DTs in the manufacturing industry and outlines the results of a systematic literature review (SLR). The identification of the state-of-the-art and the assessment of current DT concepts with regard to the addressed product lifecycle phases, technological maturity and sustainability scope point towards key directions to guide future research.

关键词： Digital Twin Sustainability Product Lifecycle Circular Economy Manufacturing

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A Practical Approach to Realize a Closed Loop Energy Demand Optimization of Milling Machine Tools in Series Production 18th

A Practical Approach to Realize a Closed Loop Energy Demand ...

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18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Can, Alperen Schulz, Hendrik El-Rahhal, Ali Thiele, Gregor Krüger, Jörg Daimlerstraße 143 Mercedes-Benz AG Berlin12277 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascal-Straße 8-9 Berlin10587 Germany

ISBN: (纸本)9783031288388

Energy efficiency is becoming increasingly important for industry. Many approaches for energy efficiency improvements lead to the purchase of new hardware, which could neglect the sustainability. Therefore, optimizing the energy demand of existing machine tools (MT) is a promising approach. Nowadays energy demand optimization of MT in series production is mainly done manually by the operators, based on implicit knowledge gained by experience. This involves manual checks to ensure that production targets like product quality or cycle time are met. With data analytics it is possible to check these production targets autonomously, which allows optimizing production systems data driven. This paper presents the approach and evaluation of a closed loop energy demand optimization of auxiliary units for milling MT during series production. The approach includes, inter alia, a concept for machine connectivity using edge devices and a concept for validating production targets. © 2023, The Author(s).

关键词： Energy efficiency

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Diamond slide burnishing for the finishing of electrical discharge machined surfaces 22

Diamond slide burnishing for the finishing of electrical dis...

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

作者： Uhlmann, E. Polte, M. Yabroudi, S. Waiblinger, N. 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)9781998999118

Electrical discharge machining (EDM) represents a key manufacturing technology in a broad range of industries, e. g. aerospace, automotive and mould making. Current industrial and scientific relevant challenges are long machining times to achieve the surface roughness values needed, excessive tool electrode wear and the related huge number of tool electrodes needed. At state of the art, the challenges mentioned strongly limit the economic efficiency of precision EDM processes. To overcome these major challenges, the substitution of time consuming EDM polishing processes by diamond slide burnishing (DSB) shows great potential. During the process, a monocrystalline spherical diamond burnishing tool is moved along the surface of the workpiece with a defined process force. In this way the surface is specifically compressed and roughness peaks are smoothed. Within this work the applicability of diamond slide burnishing for the finishing of electrical discharge machined surfaces was investigated. For this purpose, three VDI grades with different surface roughness values were subsequently machined by DSB. The results show that the surfaces with different initial surface conditions can be successfully finished by DSB. The surface roughness of VDI grade 30 is identified as an upper limit for the surface preparation by EDM. A significant improvement of the surface roughness Ra by 93 % and a reduction of the processing time by 40 % could be achieved by the post-processing using DSB. Therefore, the new process chain presented shows great potential for being used in the field of tool and mould making and especially for the production of injection moulds. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Surface roughness

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Framework of an experimental setup to enable an adaptive process control based on surrogate modelling 22

Framework of an experimental setup to enable an adaptive pro...

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

作者： Uhlmann, E. Polte, J. Bösing, M. Schuler, N. 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)9781998999118

Numerical simulations can help to reduce the necessity of experimental studies. Nevertheless, these simulations are costly in terms of their computational effort resulting in significant expenditure of time and hence prevent a flexible adaption to continuously changing process conditions in real time. To address this shortcoming, the paper describes a framework for the application of surrogate models to enable an adaptive process control in real time. Following, an experimental setup to validate the general framework is designed for a laser metal deposition process. In particular, the component distortion shall be simulated and the results are then used to train the surrogate models. By measuring the final component distortion the quality of the surrogate models can be assessed. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Process control

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Application of laser doppler vibrometry to characterize the laser drilling process 23

Application of laser doppler vibrometry to characterize the ...

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

作者： Uhlmann, Eckart Hein, Christoph Schweitzer, Luiz Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany University Medicine Greifswald Department of Orthopedics and Orthopedic Surgery Germany

ISBN: (纸本)9781998999132

Laser drilling is being used more and more frequently in many industries, such as the aerospace, medical and electronics industries, to produce precision bores. A wide range of technically difficult-to-machine materials are applied. Laser drilling has already been intensively researched in order to investigate the basic mechanisms of the drilling process and the influences of various machining parameters on the quality of the holes. These findings have explicitly led to more successful machining processes of various technical components and industries. Despite all the advantages, there are some limitations of the laser drilling process and thereby a demand for innovative solutions to increase productivity. This paper presents a novel approach to the characterisation of the laser drilling process through the analysis of the acoustic signal characteristics. The objective is to apply a new generation of optical microphones to detect key aspects of the laser drilling process. This enables the development of new strategies to optimize the laser processing parameters, increasing repeatability and productivity for industrial applications. © 2023 Euspen Headquarters.

关键词： Optimization

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