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34th CIRP Design Conference, CIRP 2024

作者： Veliu, Cäcilia Petzold, Valentin Reichelt, Dirk Stange, Maximilian Ihlenfeldt, Steffen Dresden University of Applied Sciences Friedrich-List-Platz 1 Dresden01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 Chemnitz09126 Germany Institute of Mechatronic Engineering Technical University Dresden Helmholtzstr. 7a Dresden01069 Germany

Open Source Hardware (OSH) enables innovative developments and business models. The OSH approach creates new forms of cross-company product development and community-based innovation processes. Open source has been state of the art in software industry for years. When it comes to OSH projects, however, the focus is primarily on the consumer sector. The use of OSH for industrial products, especially in mechanical engineering, is still in its early stages. The paper presents a case study on the development of an application module based on OSH components in a R&D testbed. The developed module is intended to enable electronic functional testing. For this purpose, the development process involved, among other things, creating solutions for a tool changing system. Using the case study, we analyse the advantages and disadvantages of the open source licenses used and derive implications for the R&D process. Building on this, various concepts for the use, adaptation and expansion of OSH components and the resulting implications for development processes and business models are presented. The case study is used to analyse which established open source software concepts can be transferred to material assets, but also which additional requirements arise from OSH components, e.g. in the area of safety. © 2024 The Authors. Published by Elsevier B.V.

关键词： Software testing

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Digital Twins in 3d Concrete Printing: Information Model, Enablers, and Major Challenges

SSRN

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SSRN 2024年

作者： Sokolov, Dmitrii Dementyev, Alexander Hänel, Albrecht Ihlenfeldt, Steffen Mechtcherine, Viktor Institute of Construction Materials TU Dresden Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology Dresden Germany TU Dresden Dresden Germany

The Digital Twin (DT) is one of the most promising approaches to digitalisation of industrial processes in Industry 4.0. The interconnection of two entities – a real world and its virtual replica via two-way data communication is the key feature of the Digital Twins, which should enable the handling of high complexity systems. In the field of 3D Concrete Printing (3DCP), DTs have great potential not only to improve design, construction, and maintenance of concrete structures, but foremost to facilitate technological development in regard to robustness, reliability, scalability and market readiness. Combining a pool of well-established and yet growing technologies, DTs in 3DCP deal with highly demanding materials whilst facing their own, unique challenges. This paper explores the burgeoning landscape of DT enablers, highlights their specificities in regard to integration into a DT in 3DCP, addresses particular challenges, reveals technical boundaries, and proposes possible ways to overcome some of them. © 2024, The Authors. All rights reserved.

关键词： Cyber Physical System

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Software assisted clamping point classification and position optimization for the efficient flexibilization of carbody fixtures using mathematical geometry-based search algorithms 14

Software assisted clamping point classification and position...

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14th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2020

作者： Fritzsche, Rayk Schaffrath, Robert Todtermuschke, Marcel Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The fraunhofer IWU has been developed specialized clamping robots for production of different car-models on one fixture. One of the challenges with universal clamping of different components is the contact point between part and clamping device. For the optimization of the clamping contours, a software was developed with which the geometries of the clamping points can be automatically analyzed and classified. With target search criteria, the clamping position on the component can be changed so that the clamping contours are geometrically simplified. Thus, a huge reduction in the complexity of the flexible clamping device is possible. © 2021 The Authors. Published by Elsevier B.V.

关键词： Product design

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A New Paradigm in Surface Reconstruction: LTP Features from Surface Images for Inverse Process Modeling

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Procedia CIRP 2025年 134卷 975-980页

作者： Mei Yun Liu Thomas Wiener Martin Dix Professorship Production Systems and Processes Chemnitz University of Technology Straße der Nationen 62 09111 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

This study explores the adaptation of Local Ternary Patterns (LTP) for surface reconstruction, extending its use beyond traditional texture analysis. A systematic methodology, including patch optimization, parameter optimization, and feature selection, is proposed to extract surface-relevant features from images. Applied to spark-eroded surfaces, LTP enables differentiation of surface structures, with slightly reduced classification performance for surfaces with very fine or very coarse roughness. Despite this, the method demonstrates high potential for inverse process modeling, offering a cost-effective alternative for correlating manufacturing parameters with surface characteristics, contributing to improved process optimization and quality control in precision manufacturing.

关键词： Inverse Process Model Local Ternary Patterns (LTP) Surface Reconstruction Electrical discharge machining (EDM)

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Ultrasonic assistance to reduce and monitor tool wear in deep drilling 21

Ultrasonic assistance to reduce and monitor tool wear in dee...

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

作者： Georgi, Oliver Rüger, Carlo Rentzsch, Hendrik Putz, Matthias Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9780995775190

In deep drilling, the large aspect ratio of hole depth to diameter causes problems in terms of chip formation and removal as well as tool vibrations. In addition, tool wear leads to a deterioration of process properties and decreasing process reliability. Therefore, scientific approaches aim to improve productivity and quality via a reduction of tool wear. Furthermore, methods for monitoring process conditions, specifically known as tool condition monitoring, contribute to an increase in performance. Superimposing ultrasonic vibrations to the conventional process is known as an approach with various potentials like reduced tool wear and burr formation or enhanced chip breaking behaviour. Aiming to realize in-process measurements to identify tool conditions, ultrasonic assistance enables the application of new monitoring techniques. In this context, the paper introduces a new approach to monitor tool wear using characteristic values of the resonant ultrasonic system coupled with the machining process. Experimental investigations considering deep drilling in steel 1.2311 show prove of the positive influence of ultrasonic assistance on the progress of tool wear. Furthermore, in-process measurements demonstrate that the new approach is able to monitor tool wear. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Aspect ratio

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Experimental validation of characteristic diagram-parameterization for environment-induced thermal interactions on machine tools in a climate chamber 14

Experimental validation of characteristic diagram-parameteri...

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14th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2020

作者： Kumar, Tharun Suresh Glänzel, Janine Tehel, Robert Putz, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

Thermal gradients created by environmental influences on machine tools cause considerable non-linear thermo-elastic deformations whether the machine is in operation or in idle mode. When a machine tool is subjected to changes in environmental influences such as ambient air temperature, velocity or direction, then flow (CFD) simulations are necessary to effectively quantify the thermal behavior between the machine tool surface and the surrounding air. The conventional two-step simulation procedure consisting of coupled CFD and thermo-elastic simulation is highly time-consuming especially when complex geometries are considered. Decoupling of CFD and thermo-elastic simulation can be achieved by introducing a Clustering Algorithm (CA) and Characteristic Diagrams (CDs) within the simulation workflow. Using training data obtained from a limited number of CFD simulations, the CDs can predict the heat transfer coefficients (HTCs) based on the parameterized environmental influences. This paper attempts to validate the experimental temperature and displacement readings obtained at selected positions on a machine tool using a wide range of metrological equipment such thermography camera, temperature and displacement sensors with the decoupling approach based on parameterized CDs. For investigation, the machine tool is positioned in a climate chamber, which facilitates the variation of environmental influences such as ambient temperature, flow velocity and flow direction. Initially, a precise coupled simulation model is created which is later on converted to a decoupled system using parameterized CDs. © 2021 The Authors. Published by Elsevier B.V.

关键词： machine tools

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Novel method for manufacturing herringbone gears by power skiving

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Procedia CIRP 2022年 112卷 310-315页

作者： Ruben Bauer Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenainer Str. 88 09126 Chemnitz Germany

Due to the symmetrical flank configuration, herringbone gears have no resulting axial forces and a smaller tooth width than helical gears. Because of existing manufacturing limitations, currently only double helical gears with wide center space or assembled herringbone gears are applied. In the present work, a novel machining method for herringbone gears by power skiving is presented. For this purpose, tool and technology are designed using a mathematical process model and tested subsequently. It is shown that the process can produce the required geometry with significant improvements on productivity and accuracy. Additionally, the unused center area can be eliminated.

关键词： herringbone gears power skiving gear machining process model planetary gears

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Generative design in factory layout planning 14

Generative design in factory layout planning

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14th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2020

作者： Süße, Marian Putz, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Planning and optimization of facility layouts have been investigated for decades and manifold approaches are applied for structuring and design of production layouts. However, results heavily depend on the experience and creativity of involved planning experts. Currently, complexity of planning processes constantly increases, e.g. due to further requirements of energy and media supply. Generative Design, hitherto mainly applied in component development, provides opportunities to cope with a much larger solution space and develop creative layout concepts. Thus, based on a structured overview on established planning methods, a concept and first results of factory layout planning with Generative Design are described. © 2021 The Authors. Published by Elsevier B.V.

关键词： Plant layout

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Incremental micro-forming for surface finishing with piezoelectrically actuated hammering tool with coupling unit 21

Incremental micro-forming for surface finishing with piezoel...

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

作者： Fiedler, Maik Kolouch, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9780995775190

machine hammer peening can be referred as an incremental mechanical surface treatment procedure, which can be realized by using various tools being based on various actuator principles. For the purpose of high productivity, a high-performance drive for generating vibrations in the tool of a high frequency is desired. Therefore, this paper presents a new hammer peening tool with a piezoelectric actuator. In order to facilitate this actuator principle for practical applications, a coupling unit is necessary being installed between the tool and the machine. This coupling unit insulates the process vibration at the machine (e.g. a machine tool or an industrial robot) and changes the operating mode of the hammer peening process from position controlled to force controlled. In such way, the accuracy of the positioning movement as well as the accuracy of the workpiece are not the issue anymore and the piezoelectrically actuated tool with a low stroke of 120 µm can be deployed for practical applications. This tool together with the coupling unit can reach hammering frequencies in the range from 800 to 1300 Hz. These frequencies enable higher feed rates and productivity of the hammer peening process than tools with pneumatic or electromagnetic actuators being available on the market. For the purpose of demonstration of the tool potential, some experimental tests are presented in this paper. Here, workpiece being milled like in die making were treated by the hammer peening process with the new tool. The surface were smoothed from Ra 1.18 μm to Ra 0.10 μm. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Piezoelectric actuators

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Coupled CFD model of tool environment and workspace to determine the convective heat transfer in jet cooling of milling processes in machine tools

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Procedia CIRP 2025年 133卷 280-285页

作者： Steffen Brier Alexander Geist Janine Glänzel Christian Naumann Joachim Regel Martin Dix Steffen Ihlenfeldt Chemnitz University of Technology Professorship Production Systems and Processes Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Technical University Dresden Institute for Machine Tools Development and Adaptive Controls Helmholtzstraße 10 01069 Dresden Germany

The responsible use of resources is an essential part of the manufacturing of industrial products. This includes the economical use of cooling lubricant and requires precise knowledge of the cooling mechanisms and their effect on the accuracy of the machine tool and thus the thermal error. A temporal and spatial resolution of the dynamic coolant flow near the tool and in the entire workspace in a single model would require a large simulation time. Therefore, a composite model was developed, that consists of a near-tool model and a larger surrounding workspace model. The required static near-tool cooling lubricant distribution is obtained via data discretization methods from a separate static simulation that resolves the turbulence of the cooling lubricant created by the tool rotation. The identified coolant distribution is integrated into a CFD near-tool model (with simplified tool geometry) which is coupled with a surrounding CFD workspace model. The workspace model is thus able to identify the effects of the coolant wetting on the machine surface temperature and finally, using thermo-elastic FEM simulations, on the resulting thermal error. This approach allows the composite model to simulate the entire workspace with reduced simulation effort and map the coolant-influenced heat transfer coefficients on the machine surface.

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