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Dry sheet metal forming of aluminum by smooth DLC coatings – a capable approach for an efficient production process with reduced environmental impact

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Procedia Manufacturing 2020年 43卷 642-649页

作者： T. Abraham G. Bräuer F. Flegler P. Groche M. Demmler Fraunhofer-Institut for Surface Engineering and Thin Films Bienroder Weg 54E 38108 Braunschweig Germany Institute for Production Engineering and Forming Machines Technische Universität Darmstadt 64287 Darmstadt Germany Fraunhofer-Institut for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

Currently a high amount of lubricants is used in aluminum forming processes to ensure a long tool lifetime and a high product quality. These technological and economical goals are traded for a negative environmental impact caused by the usage of lubricants. One approach to reduce the environmental impact is the utilization of dry forming of aluminum. Therefore, alternative methods for a tribological optimization need to be implemented like the deposition of tool coatings. Diamond like carbon (DLC) coatings are well known for their exceptional tribological properties. However, state of the art DLC coatings fail due to rapid formation of aluminum adhesions. In this paper, the nanoscopic roughness of DLC coatings will be presented as a critical property for preventing the formation of aluminum adhesions and enabling dry forming of aluminum. For this purpose, an amorphous hydrogenated carbon (a-C:H) coating will be deposited, subsequently polished and characterized to validate the impact of the material selection and surface treatment on the coating roughness. For an evaluation of the tribological properties, polished and unpolished a-C:H coatings will be tested in application oriented strip drawing and industry-oriented deep drawing tests. These tests demonstrate the capability of smooth a-C:H tool coatings to enable dry forming of aluminum with a reduced environmental impact.

关键词： Tribology Coating Metal forming

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Digital service application for the recalibration of a machine tool through Augmented Reality-supported data acquisition

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IOP Conference Series: Materials Science and Engineering 2022年第1期1235卷

作者： F Arnold G Lemme M Hess S Witt S Ihlenfeldt Institute of Mechatronic Engineering Chair of Machine Tools Development and Adaptive Controls TU Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Dresden Germany Software AG Darmstadt Germany METROM Mechatronische Maschinen GmbH Hartmannsdorf Germany

The effort for checking and correcting the spatial movement accuracy of a processing machine with 5 axes is very high. Calibration and recalibration must be carried out directly on the machine by the machine supplier or a company specializing in this. This is associated with high personnel and long machine downtimes. These constraints can be improved by using modern methods. A consistent approach of an AR-supported measurement procedure for the preparation and execution of a required measurement run and the execution of the calibration itself as a digital service is presented. This enables rapid execution by the machine operator himself using a DoubleBallBar measurement system without the need of the presence of the machine manufacturer. The determination of the calibration parameters on the basis of the measurement data is then carried out by the machine manufacturer and provided as a service. The basis for such a secure and auditable service is a digital service platform. This serves as an intermediary between the user and the machine manufacturer and uses distributed ledger technology. The approach presented is the subject of current development work.

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Data Mining and machine Learning Methods Applied to A Numerical Clinching Model

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Computer Modeling in Engineering & Sciences 2018年第12期117卷 387-423页

作者： Marco Gotz Ferenc Leichsenring Thomas Kropp Peter Müller Tobias Falk Wolfgang Graf Michael Kaliske Welf-Guntram Drossel Institute for Structural Analysis Technische UniversitatDresdenGermany Fraunhofer Institute for Machine Tools and Forming Technology DresdenGermany

Numerical mechanical models used for design of structures and processes are very complex and high-dimensionally *** understanding of the model characteristics is of interest for engineering tasks and subsequently for an efficient *** analysis methods are known and available to gain insight into existing *** this contribution,selected methods from various fields are applied to a real world mechanical engineering example of a currently developed clinching *** selection of introduced methods comprises techniques of machine learning and data mining,in which the utilization is aiming at a decreased numerical *** methods of choice are basically discussed and references are given as well as challenges in the context of meta-modelling and sensitivities are *** incremental knowledge gain is provided by a step-bystep application of the numerical methods,whereas resulting consequences for further applications are ***,a visualisation method aiming at an easy design guideline is *** visual decision maps incorporate the uncertainty coming from the reduction of dimensionality and can be applied in early stage of design.

关键词： Design data mining computational intelligence meta-modelling permissible design space sensitivity analysis self-organizing maps inverse problem early stage of design clinching

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Influence of cutting edge radius on process forces in orthogonal machining of carbon fibre reinforced plastics (CFRP)

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Procedia CIRP 2019年 85卷 218-223页

作者： Konstantin Sauer Marco Witt Matthias Putz Institute for Machine Tools and Production Processes Chemnitz University of Technology 09111 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

Carbon fibre reinforced plastics (CFRP) are commonly used in the aerospace and automotive industries to reduce the mass of parts and assemblies with the goal of improving energy efficiency. When machining with geometrically defined cutting edge, the cutting edge radius of the tool is a quality-determining feature and should be kept as low as possible to enable precise separation of the fibres. It is raised by the use of coatings and by cutting edge wear. The aim of this paper is to evaluate the influence of the cutting edge radius on thrust force and cutting force when machining CFRP using an orthogonal cut. It is intended to map the drilling process by means of an orthogonal cut at certain fibre cutting angles. A new method of orthogonal machining has been developed for this purpose that considers the fibre preload and the feed movement of a drill. The fibre orientation was varied in the tool cutting edge plane. The application of small depths of cut in combination with different cutting edge radii enable the investigation of the effect of different cutting edge regions on the process forces. For this purpose, a new method for cutting edge preparation is proposed, based on the abrasive waterjet. Accordingly, the paper increases the understanding of the process when machining with high cutting edge radius.

关键词： Composite Cutting edge Machining Orthogonal cut CFRP Process force

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Manufacturing of glass fibre/PBT-spincom yarns for innovative composite processing 18

Manufacturing of glass fibre/PBT-spincom yarns for innovativ...

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18th European Conference on Composite Materials, ECCM 2018

作者： Scheffler, Christina Hiller, Janett Krüger, Matthias Haase, Rico Weise, Dieter Garray, Didier Spickenheuer, Axel Leibniz-Institut für Polymerforschung Dresden e.V. Dept. Composite Materials Hohe Straße 6 Dresden01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dept. Business Unit Car Bodies and Cell Structures Chemnitz Germany SIRRIS Seraing Liège/Wallonia Belgium

ISBN: (纸本)9781510896932

The aim of this work was the development of GF (glass fibre)/ PBT (polybutylene therephthalate) SpinCOM yarns that are commingled online during the spinning process using sizing formulations that enable textile processability as well as high fibre-matrix interaction. Epoxy- and polyurethane-based sizings have been applied and were evaluated by micromechanical (single fibre pull-out test) and macromechanical (transverse tensile test of unidirectional plates) testing. Finally, a material combination was selected to be processed by Tailored Fiber Placement (TFP) to textile preforms with a variable-axial, load adapted fiber design. These preforms were consolidated in a low energy and resource consuming process using novel light and low cost forming tools produced by incremental sheet metal forming (ISF) technology. Finally, a low cost solution for thermal processing even for complex shaped TPC parts is demonstrated by the geometry of a bicycle saddle. © CCM 2020 - 18th European Conference on Composite Materials. All rights reserved.

关键词： Polybutenes

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A Survey on Automatic Model Generation for Material Flow Simulation in Discrete Manufacturing

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Procedia CIRP 2019年 81卷 121-126页

作者： Heiner Reinhardt Marek Weber Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany

Adaptivity of production systems is acknowledged as a key competition factor in the manufacturing industry. In order to decrease reaction time and increase cost efficiency, changes to a production system are often planned and validated using material flow simulation. However, repeated manual synchronization of the simulation model with the real manufacturing environment is time-consuming and error-prone. Automatic simulation model generation (ASMG) could overcome these issues. In contrast to recent surveys on ASMG, we focus on information retrieval. Accordingly, we constitute the state of the art of this problem domain and outline future research directions.

关键词： Digital Manufacturing System Simulation Modeling Automation

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Monitoring concept for structural integration of PZT-fiber arrays in metal sheets:a numerical and experimental study

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International Journal of Smart and Nano Materials 2018年第1期9卷 56-67,I0003页

作者： Welf-Guntram Drossel Andreas Schubert Matthias Putz Hans-Joachim Koriath Volker Wittstock Sebastian Hensel Alexander Pierer Benedikt Müller Marek Schmidt Fraunhofer Institute for Machine Tools and Forming Technology ChemnitzGermany Professorship for Adaptronics and Lightweight Design Chemnitz University of TechnologyChemnitzGermany Professorship Micromanufacturing Technology Chemnitz University of TechnologyChemnitzGermany Professorship for Machine Tools and Forming Technology Chemnitz University of TechnologyChemnitzGermany

The technique joining by forming allows the structural integration of piezoceramic fibers into locally microstructured metal sheets without any elastic interlayers.A high-volume production of the joining partners causes in statistical deviations from the nominal dimensions.A numerical simulation on geometric process sensitivity shows that the deviations have a high significant influence on the resulting fiber stresses after the joining by forming operation and demonstrate the necessity of a monitoring *** this basis,the electromechanical behavior of piezoceramic array transducers is investigated experimentally before,during and after the joining *** piezoceramic array transducer consists of an arrangement of five electrical interconnected piezoceramic *** findings show that the impedance spectrum depends on the fiber stresses and can be used for in-process monitoring during the joining *** on the impedance values the preload state of the interconnected piezoceramic fibers can be specifically controlled and a fiber overload.

关键词： Impedance spectroscopy joining by forming process monitoring function integration sensitivity

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Haptic feedback is more important than VR experience for the user experience assessment of in-car human machine interfaces 31st

Haptic feedback is more important than VR experience for the...

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31st CIRP Design Conference 2021, CIRP Design 2021

作者： Schölkopf, Lasse Lorenz, Mario Stamer, Mareike Albrecht, Lina Klimant, Philipp Hammer, Niels Tümler, Johannes Volkswagen AG Berliner Ring 2 Wolfsburg38436 Germany Professorship for Production Systems and Processes Chemnitz University of Technology Reichenhainer Straße 70 Chemnitz09126 Germany Department of Orthopedics Trauma and Plastic Surgery University Hospital Leipzig Liebigstraße 20 Leipzig04103 Germany Department of Macroscopic and Clinical Anatomy Medical University of Graz Harrachgasse 21 Graz8010 Austria Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Professur Ingenieurinformatik Anhalt University of Applied Sciences Bernburger Str. 55 Köthen06366 Germany

The user experience (UX) of a product is important for a customer's decision, especially in the automotive sector. In recent years, a frontloading of UX assessments from physical prototypes to virtual prototypes has occurred. Nevertheless, there are clear indications that established UX assessments methods cannot simply be transferred 1-to-1 from real to virtual evaluation setups as results get biased. For the UX assessment of an in-car human machine interface (HMI) the haptic properties of the knobs and buttons are just as important as their visual features. Therefore, it is mandatory to also simulate the haptic behavior of the in-car HMI in virtual reality (VR) assessment scenarios. However, accurately simulating this haptic behavior adds considerable costs and effort, diminishing the beneficial effects of VR UX assessments. Due to confidentiality reasons the volunteering participants of VR UX studies in the automotive sectors are typically employees with a varying degrees of VR experience. It is unknown if this gap in VR experience biases the results of UX assessments in VR. This paper presents a UX assessment study of an in-car HMI in VR in comparison to reality. From a practitioners viewpoint two research question are investigated: (1) How much is the UX assessment impaired by missing haptic simulation? (2) Does VR experience influence UX assessment ratings in VR? The results show that missing haptic feedback severely diminishes UX ratings, leaving no doubt that meaningful UX assessments in VR can only be performed when haptic is included. This means that more effort has to be put into earlier VR assessments severely reducing its benefits compared to UX assessments with physical prototypes. However, the VR experience of the participants only has a slight effect on the UX assessment results. © 2021 Elsevier B.V.. All rights reserved.

关键词： Virtual reality

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Inverse hybrid laminate for lightweight applications 5th

Inverse hybrid laminate for lightweight applications

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5th International Conference on Composite Materials and Material Engineering, ICCMME 2020

作者： Osiecki, Tomasz Gerstenberger, Colin Timmel, Tristan Frankiewicz, Mariusz Dziedzic, Robert Scholz, Peter Kroll, Lothar Institute of Lightweight Structures and Polymer Technology Technische Universität Chemnitz Reichenhainer Str. 31-33 Chemnitz09126 Germany Wroclaw University of Science and Technology ul. Lukasiewicza 5 Wroclaw50-371 Poland Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Opole University of Technology Prószkowska 76 Street Opole45-758 Poland

ISBN: (纸本)9783035716191

Because of their high specific stiffness and strength, fiber reinforced plastics (FRP) are preferred lightweight materials. Recent developments show a growing industrial interest in the integration of thermoplastic FRP in complex structures for high volumes. However, there are still shortcomings for these materials concerning the insufficient energy absorption in case of failure and the limited opportunities available for the assembly with other components. Improvements in the crash performance can be achieved for instance with the selective reinforcement of the FRP structure with ductile metallic inserts. The present study shows the interlaminar shear strength and scanning electron microscope (SEM) samples of a novel load optimized hybrid composite consisting of a continuous fiber-reinforced thermoplastic matrix, in which a metal core is integrated. © 2020 Trans Tech Publications Ltd, Switzerland.

关键词： Fiber reinforced plastics

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Additive manufacturing technologies for next-generation powertrains

Additive manufacturing technologies for next-generation powe...

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International Electric Drives Production Conference (EDPC)

作者： Philipp Fiedler Sebastian Stelzer Nikolaus Milaev Robert Richter Frank Kaulfuß Thomas Windisch Jan Bräunig Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany 3D-Printpetrol Großenhain Germany Fraunhofer Institute for Material and Beam Technology IWS Dresden Germany Division Engineering of Adaptive Systems Fraunhofer IIS/EAS Fraunhofer Institute for Integrated Circuits Dresden Germany

ISBN: (数字)9781728184586

ISBN: (纸本)9781728196145

The paper addresses the prototypical development and implementation of an innovative and functionally integrated gear stage for next-generation electric vehicles, produced by using Laser Beam Melting (LBM) and Fused Deposition Modeling (FDM). Two new design targets are addressed by our approach: Oil-free operation is achieved by innovative coating of gear teeth which enables almost maintenance-free operation. Furthermore, a higher damping of sound transmission from tooth mesh to bearings is implemented by an optimal wheel body geometry that is realized by a combination of printable carbon-containing polymers (flange) and steel (gear rim). The innovative approach is to extend components by areas that cannot be produced by milling and casting, e.g. complex structures, contour-following fluid-carrying cooling elements by means of LBM, thus creating a significant benefit compared to state-of-the-art gearboxes. Function integration made possible by additive manufacturing results in a very high component complexity. It is combined with gear grinding and final ta-C coatings ensuring maximum efficiency in dry operation, to achieve economically viable production processes. The increase in tooth mesh efficiency is achieved by optimization approaches in the design to minimize heat losses while at the same time maintaining highest possible strength and lowest noise emission.

关键词： Gears Wheels Production Three-dimensional printing Laser beams Coatings Next generation networking

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