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Development of a material selection decision support system for an automotive application

Discover Mechanical Engineering 2024年第1期3卷 1-21页

作者： Chirinda, Gibson P. Matope, Stephen Nagel, Matthias University of Stellenbosch Private Bag X1 Matieland Stellenbosch 7602 South Africa Fraunhofer Institute of Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

This study presents the development of a material selection decision support system for an automotive rooftop tent. The system uses five parameters of material cost, formability, corrosion resistance, tensile strength and hardness to optimize material choice from a list of aluminium alloy options. This was done before production via the deep drawing process can commence. The parameters were quantified using the average market prices for each alloy, product requirements obtained from the case study and the performance data that was obtained from the uniaxial tensile and hardness tests. These inputs were combined with the developed material selection framework and then programmed into a web-based decision support system for automated, data-driven material selection. The output presents the recommendation for the optimum material that balances cost-effectiveness and performance. The decision support system was successfully used to select the optimum alloy for the rooftop tent. Results show that AA1050 is the optimum material, providing weight reduction at the minimum achievable cost without compromising the product requirements for the rooftop tent. The decision support system is also scalable, and this allows it to be used with larger datasets for different products and processes in the future. © The Author(s) 2024.

关键词： Aluminium alloy Automotive industry Decision support system Deep drawing Lightweighting Material selection

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Investigation of Surface Characteristics in Magnetic Field assisted Electrical Discharge Machining 7

Investigation of Surface Characteristics in Magnetic Field a...

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7th CIRP Conference on Surface Integrity, CSI 2024

作者： Bui, Viet D. Martin, André Berger, Thomas Schubert, Andreas Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

Electrical discharge machining (EDM) has demonstrated its promising potential for surface modification. The integration of materials from tool electrode or powder that is mixed into the dielectric fluid has proven to modify the workpiece surface to enhance its mechanical properties, realize antibacterial effects, or increase biocompatibility. Recent EDM studies showed that due to non-contact forces, properties of the modified surface such as roughness values and the thickness of modified layer were significantly influenced when using magnetic field assisted EDM. Consequently, in this study, an external magnetic field with a strength of 0.66 T is used to assist the material transfer from tool electrode to workpiece surfaces during the EDM process. Pure silver and copper tools with a diameter of 2 mm are used to modify surfaces of Ti6Al4V workpieces at a discharge energy of 125 µJ with different polarities. Results show that the assistance by magnetic field significantly increases the content of transferred material from tool electrode to the workpiece surface. Additionally, it increases material removal rate and reduces the modified layer thickness. Magnetic field assisted EDM is a potential technology for improving the efficacy of the EDM surface modification. © 2024 The Authors. Published by Elsevier B.V.

关键词： Titanium alloys

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Simulation of geometrical errors during application of a confocal sensor system for the measurement of large components with high aspect ratios 15

Simulation of geometrical errors during application of a con...

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15th International Conference and Exhibition on Laser Metrology, Coordinate Measuring machine and machine Tool Performance, LAMDAMAP 2023

作者： Teicher, Uwe Gollee, Christian Seidel, André Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

ISBN: (纸本)9781998999125

Machining of large components for the aerospace industry requires, in addition to sophisticated machining strategies a targeted monitoring of the machining quality due to the enormous demands on precision. For the acquisition of the as-is geometry after single machining steps, a non-contact system based on a confocal chromatic sensor was developed, with whose help the as-is geometry can be compared with the target geometry even in deep cavities at aspect ratios up to 40. The sensor system is coupled with the standard interfaces to a machine tool and performs measuring cycles based on modified NC programs. Data acquisition is done with a control-connected EDGE system. The result of the target/as-is comparison is the basis for CAM planning for subsequent machining. In addition to the design of the measuring system and the integration into the ecosystem of the machine system, a concept to calibrate the measuring system for operation on the machine tool was developed. Based on a simulation model of the measurement system various aspects of the calibration approach were analysed. © euspen Headquarters March 2023.

关键词： Geometry

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Antibacterial Surface Protection using Electrical Discharge Machining with Zinc Tool Electrode for Medical Devices 6

Antibacterial Surface Protection using Electrical Discharge ...

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6th CIRP Conference on BioManufacturing, BioM 2024

作者： Bui, Viet D. Martin, André Berger, Thomas Steinert, Philipp Schubert, Andreas Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

Electrical discharge machining (EDM), widely used to fabricate medical devices, is applicable for antibacterial surface protection. Silver, transferred from tool electrode or powder suspended in the dielectric to the modified layer during the EDM process, significantly enhanced antibacterial properties of the modified surface. However, bacterial resistance to silver, which was widespread in clinical, still posed challenges for the modified surfaces containing silver. Zinc, owing to its strong antibacterial effects and no challenge related to Zn-resistant bacteria hitherto reported in clinical, was therefore used as tool electrode material to modify Ti6Al4V surfaces during the EDM process. Discharge energies up to 170 ìJ with different polarities were applied in the EDM milling process using deionized water-based dielectric fluid. Results show that discharge energy and polarity play a vital role in chemical composition and roughness of the modified surfaces as well as material removal rate and tool wear rate. The surfaces containing zinc contents up to 28 % can be generated. The use of a low energy generates zinc-rich surfaces with less micro-cracks. The EDM process using zinc tool electrode shows a promising potential for antibacterial surface modification of medical devices. © 2024 The Authors.

关键词： Deionized water

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Operational modal analysis used to identify dynamic behaviour of machine tools during milling 16

Operational modal analysis used to identify dynamic behaviou...

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16th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2022

作者： Berthold, Jan Regel, Joachim Dix, Martin Drossel, Welf-Guntram Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

The dynamic behaviour of machine tools during cutting is investigated by Operational Modal Analysis (OMA), which overcomes the disadvantages of the Experimental Modal Analysis (EMA) using excitation methods such as shakers or hammers, not considering effects occurring during operation. The assumptions of OMA such as time-invariance and white noise excitation are difficult to fulfil considering the boundary conditions of a milling process. The results show that feed motions classify the varying dynamic behaviour in the working space and excitation is controlled by modification of the milling conditions. Modal Parameters, identified by OMA, provide process-related results enabling to improve performance. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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Synthetically Generated Images for Industrial Anomaly Detection 29

Synthetically Generated Images for Industrial Anomaly Detect...

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29th IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2024

作者： Wagenstetter, Marco Gospodnetic, Petra Bosnar, Lovro Fulir, Juraj Kreul, Donovan Rushmeier, Holly Aicher, Thomas Hellmich, Arvid Ihlenfeldt, Steffen Powertrain Production System Planning Bmw Group Germany Synthetic Data Generation Fraunhofer Itwm Germany Yale University Synthetic Data Generation United States Machine tools and forming technology Fraunhofer Iwu Germany

ISBN: (纸本)9798350361230

Automation of inspection for quality control is needed to overcome the errors and delays inherent in manual processes. machine learning methods have the potential to greatly improve automated inspection. However, machine learning techniques require training data that are precisely labeled and reflect the distribution of defects to be detected. Physically collecting suitable training data requires significant time and prolongs the overall time for system development. To address this challenge, a new study is presented that explores synthetic data generation for a state-of-the-art anomaly detection (AD) model in the electric motor housing (EMH) surface inspection. The study successfully demonstrates using synthetic data for anomaly detection and presents a comparison of detection performance by models trained solely on synthetic data and models trained on both synthetic and real data. The study shows that real data combined with synthetic data can increase overall model performance. The study also addresses current challenges in using synthetic data and proposes directions for future work. © 2024 IEEE.

关键词： Adversarial machine learning

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Innovative actuating process for machining CFRP with force-controlled radial feed movement 33

Innovative actuating process for machining CFRP with force-c...

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33rd CIRP Design Conference

作者： Peter, Marie Sauer, Konstantin Regel, Joachim Dix, Martin Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

The use of lightweight materials such as carbon fibre reinforced plastics (CFRP) is increasing due to the demand for rising resource and energy efficiency, especially in the aerospace and automotive industries. Because of the high delamination tendency of these materials and their abrasive impact on the tool, the challenges in machining CFRP lie primarily in the drilling process and thus in the design of the drilling tool. In this paper, an innovative design of a drilling tool for machining CFRP with force-controlled radial feed movement of the cutting edges is presented. The aim of this tool is to create a tool axial force free process that uses a force-controlled radial feed motion, which matches the chip cross-section to the wear condition of the cutting edge. The tool concept is explained based on the functionality of the actuating process. Tests were evaluated with regard to process forces and drilling quality to show that the tool is capable of producing delamination-free bores in a tool axial force free process. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://***/licenses/by-nc-nd/4.0)

关键词： Carbon fiber reinforced plastics

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Influence of the cutting edge preparation of carbide punching tools for punching of ultra-high strength steel strips 7

Influence of the cutting edge preparation of carbide punchin...

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7th CIRP Conference on Surface Integrity, CSI 2024

作者： Redžić, Nermin Winter, Sven Galiev, Elmar Baron, Sarah Stein, Christian Höfer, Markus Regel, Joachim Kräusel, Verena Dix, Martin Chemnitz University of Technology Institute for Machine Tools and Production Processes IWP Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Riedenkamp 2 Braunschweig38108 Germany

In order to ensure a robust punching process of ultra-high strength steel spring strips using carbide punching tools, a high stability of the cutting edge is required. Here the cutting edge preparation process has a significant influence. In the presented study, high-pressure abrasive water jet technology for cutting edge preparation was designed, investigated and analysed. For defining the optimal cutting edge shape regarding stresses, a numerical analysis using LS-DYNA was conducted. Within this analysis, the influence of the cutting edge rounding and symmetry was numerically tested and evaluated. Based on the results, two cutting edge shapes were selected and prepared using the high-pressure abrasive water injection jet technology. The tools were applied in the punching process up to 50, 000 strokes in order to analyse the cutting performance and tool wear. With regard to a highly wear resistant tool for punching, a combination of the abrasive water injection jet preparation routine and a CVD diamond coating are under further investigation and first insights are presented additionally. © 2024 The Authors. Published by Elsevier B.V.

关键词： High strength steel

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Experimental setup for evaluation of electrical face contacts for high-current applications

Experimental setup for evaluation of electrical face contact...

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Production Technologies and Systems for E-Mobility (EPTS), International Conference on

作者： Sebastian Wieland Tingyan Sun Lars Kanzenbach Jörg Schneider Jan Edelmann Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (数字)9798350386172

ISBN: (纸本)9798350386189

The transmission of high electrical power via separable contact connections is a key challenge in the context of the energy transition. A well-known example is the charging interface of electric vehicles. To counteract the presently long charging time of battery systems, an innovative fast charging system using a face contact instead of classic plug-in contacts is being developed. To enable charging power in the megawatt range, an electrical contact surface is functionalized in such a way that, on the one hand, the contact resistance is reduced and, on the other hand, the thermal as well as the mechanical properties are improved. In addition to the simulation-based design of the contact surfaces and the development of manufacturing technologies, the required measurement and testing technology is a fundamental challenge. In this article the experimental setup for the long-term test of the electrical face contacts is being introduced. Using the test bench, electrical contacts can be automatically evaluated with regard to their temperature development and contact resistance at normal forces of up to 500 N with a current load of up to 600 A DC under constant or cyclic conditions. In this context the test procedure as well as first results of the thermo-mechanical properties of a face contact setup are being discussed.

关键词： Temperature measurement Temperature Surface resistance Thermal resistance Thermomechanical processes Surface charging Contact resistance

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Intuitive Robot Programming and Intelligent tools

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IST International Surface technology 2023年第2期16卷 8-9页

作者： Bdiwi, Mohamad Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Chemnitz Germany

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