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检索条件"机构=Fraunhofer-Institut for Machine Tools and Forming Technology"

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Modeling of tool load for optimization of tool life in diagonal generating grinding 19

Modeling of tool load for optimization of tool life in diago...

引用

19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Rößler, Maximilian Krage, Robin Dix, Martin Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Diagonal continuous generating grinding with ceramic bonded wheels is commonly used for hard finishing of automotive gears with topological modifications. In this process, areas of the grinding wheel have to be used repeatedly to machine multiple components, resulting in not achieving the same tool life as conventional generating grinding. This paper presents a detailed process model predicting loads on the wheel as a basis for an optimization of tool life. Based on a redistribution of the roughing and shifting areas of the grinding wheel, significantly lower wear could be demonstrated in tests. © 2023 Elsevier B.V.. All rights reserved.

关键词： Grinding (machining)

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Simulation tool for chatter prediction of varying tool-machine configurations based on dynamic substructuring 19

Simulation tool for chatter prediction of varying tool-machi...

引用

19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Schuster, Alexander Sahu, Govind N. Rentzsch, Hendrik Otto, Andreas Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

Cutting tools of different type, shape and size are used in milling processes. Every individual tool changes the dynamic behavior of the system and results in varying occurrences of chatter vibrations. This paper presents a simulation tool using a frequency based substructuring method for predicting the process stability without separate measurements of the tool-machine configuration. In particular, frequency response functions of any combined tool-machine configuration is synthesized by the receptance coupling substructure analysis. It enables the calculation of critical machining parameters and maximizing material removal rates by avoiding unstable cutting conditions. Verification is done via finite element analysis of exemplary tool and machine structures. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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A survey on smart product-service systems in manufacturing 56

A survey on smart product-service systems in manufacturing

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56th CIRP International Conference on Manufacturing Systems, CIRP CMS 2023

作者： Mauersberger, Anton Alaluss, Mohaned Beyer, Antonia Nölscher, Kilian Armin Rauscher, Alexander Reinhardt, Heiner Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The advancing digitization affects product design and manufacturing. Companies focus on product-service systems (PSS) to improve customer satisfaction and loyalty. However, these PSS become increasingly complex as digital technologies are incorporated and cross-company collaboration and manufacturing is facilitated. In essence, we can observe a transition from conventional PSS to smart PSS, where the opportunities of digitization are effectively utilized and synergies between multiple stakeholders are fostered. Here, we present an analysis and classification of smart PSS considering aspects of business modeling, composition, design, quality and sustainability. © 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) Peer-review under responsibility of the scientific committee of the 56th CIRP International Conference on Manufacturing Systems 2023.

关键词： Decision making Development Innovation management Modular design Product-service system Production Remote service Smart PSS Smart service Smart technologies

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Tool wear monitoring in milling processes using a sensory tool holder 23

Tool wear monitoring in milling processes using a sensory to...

引用

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

作者： Schuster, Alexander Otto, Andreas Rentzsch, Hendrik Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9781998999132

In-process monitoring in milling, specifically tool condition monitoring (TCM), is an important technology for improving productivity and workpiece quality. However, industrial implementation of in-process TCMs remains a difficult task, since progressing tool wear is indicated by small changes of various physical parameters. Therefore, a sensitive monitoring system is needed to provide a reliable base of information while having minimal impact on the machine tool system and processes. Recent advancements in deep learning (DL) techniques are frequently applied on monitoring data for tool wear prediction as they can process and analyse raw data without prior feature engineering. This paper presents a suitable monitoring approach based on a recently developed sensory tool holder, which measures cutting forces and vibrations in direct proximity to the process zone. The system is equipped with wireless data transmission and a novel energy harvesting technology for energy supply. Two milling experiments with focus on increasing tool wear were conducted and the collected data processed. A DL based model, comprising three convolutional neural network (CNN) layers, one long short-term memory (LSTM) layer, and a multi-layer perceptron (MLP), was trained on the raw sensor signals to make predictions on the tool wear state. The model was evaluated using previously unseen test data and achieved a high prediction accuracy of at least 97,3% for all sensor signals, with the highest accuracy of 99,9% achieved when using bending moment signals. © 2023 Euspen Headquarters.

关键词： Milling (machining)

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Joining of Laminated Core and Shaft of an Electric machine Rotor by Electromagnetic forming

Joining of Laminated Core and Shaft of an Electric Machine R...

引用

International Electric Drives Production Conference (EDPC)

作者： Verena Psyk Linda Fleischer Maik Linnemann Mirko Bach Martin Dix Department Forming Technology Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (数字)9798350356885

ISBN: (纸本)9798350356892

In the mobility industry and especially in case of electrically powered vehicles the implementation of lightweight powertrain components with high efficiency and minimum in-stallation space is of utmost importance. One approach to realize a particularly compact and light design is using a central motor, which is aligned with a planetary gearbox via coaxial (partly) hollow rotor shafts positioned one within the other to operate the left and right-hand wheels of the car. To enable further weight reduction, aluminium alloys might be considered for the hollow shafts instead of the conventionally used steel. When the electrical machine is assembled, the shafts must be firmly connected to the rotor core, which is typically made of laminated electrical steel core. Electromagnetic forming is a promising technology for joining tubular aluminium components with similar or dissimilar materials. In this paper, the suitability for the described joining task is investigated. For this purpose, an inductor specifically suitable for expanding a round tube into a non-rotationally symmetric cross section shape is suggested and the corresponding joining process is developed using coupled electromagnetic and structural mechanical simulation. Experimental validation is carried out using a technology demonstrator.

关键词： Shafts Space vehicles Shape Rotors Wheels Mechanical power transmission Topology Steel Electromagnetics Joining processes

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Methods for the environmental and economic assessment in early product design - A case study-based overview for wind turbines in urban areas 31

Methods for the environmental and economic assessment in ear...

引用

31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Zumpe, Martin Stange, Maximilian Burak Ertem, Ahmet Süße, Marian Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The assessment of environmental impacts has become an inevitable necessity for many manufacturing companies - not only from a mere retrospective viewpoint but also for product design decisions. At the same time, economic feasibility must be constantly considered throughout all product design phases. For both dimensions, many different decision-support methods exist. However, there is a lack of combined assessment methods especially in early product design phases, when product characteristics, manufacturing technologies and corresponding data are still uncertain. The paper provides an overview and qualitative evaluation of different methods for economic and ecological assessment in product design stages. Based on this, a generalized procedure for combined economic and ecological decision-making during product design is derived, highlighting possible coping mechanisms for uncertain or insufficient data. Both, the evaluation of available assessment methods as well as the derived procedure are transferred to the specific requirements of wind turbines in urban areas. As a result, open research aspects and the next steps for method development are derived. © 2024 The Author(s).

关键词： Product design

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Combining material flow simulation and optimization for sustainable manufacturing - Application in automotive paint shops 31

Combining material flow simulation and optimization for sust...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Süße, Marian Xie, Xinyi Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The necessity for sophisticated decision support in industrial manufacturing has been described manifoldly and simulation approaches as well as optimization methods are continuously developed. This can be especially promising when it comes to decision-making with multidimensional requirements of economic and ecological efficiency. However, due to the required expert knowledge, there is still a gap between theoretically applicable and industrially applied methods. The paper therefore presents results of two use cases as part of the European project ECOFACT where different approaches for the combination of simulation and (heuristic) optimization were applied with industry partners. An overview of recent works and systematic literature reviews of sustainable manufacturing and the approaches for combining simulation and optimization is given. Correspondingly, the investigated use cases of automobile paint shops refer to the reduction of environmental impacts by optimized heating processes and an improved batching process to minimize paint waste. In the first case, setup times for heating color pools and ovens were shifted to avoid load peaks in a calculation time of less than one minute. In the second use case batch size was increased by around 25%. © 2024 Elsevier B.V.. All rights reserved.

关键词： Paint

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Dismantling and remanufacturing strategies in the automotive sector 31

Dismantling and remanufacturing strategies in the automotive...

引用

31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Haase, Rico Farioli, Daniele Selbmann, Rene Werner, Markus Kräusel, Verena Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz09126 Germany Politecnico di Milano Department of Mechanical Engineering Milan20156 Italy

The contemporary recycling of automobiles takes place on a very baseline material level. In order to fundamentally improve the ecologic footprint of the vehicle, a wider application of remanufacturing strategies is intended. Following different recycling approaches ranging from direct reuse or refurbishment through remanufacturing until repurpose, a well-aimed dismantling followed by manufacturing processes adapted to the post-consumer components is mandatorily required. For use on an industrial scale, environmental efficiency and economic viability must be balanced well. Within the paper, possible remanufacturing technologies and necessary prerequisites such as input data are discussed. For the design of remanufacturing operations, material properties and geometric information are a crucial starting point. Seamless integration of the specific properties is intended to encourage wider utilization of pre-used components and materials. With reference to the well-established process design for metal forming operations, adapted material cards and curvature equivalence values are proposed. The approach is illustrated by a reforming operation, where a brake disc cover is remanufactured from a used car body roof. © 2024 Elsevier B.V.. All rights reserved.

关键词： Recycling

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Energy self-sufficient, multi-sensory tool holder for sensitive monitoring of milling processes 19

Energy self-sufficient, multi-sensory tool holder for sensit...

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19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Schuster, Alexander Rentzsch, Hendrik Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

Machining processes, especially milling, place several requirements on monitoring systems. Two prevalent ones are minimal implications towards the machine tool system and direct proximity to the machining zone to acquire high signal quality. Thereby, sensitive detection of even minor process alterations is enabled. This paper presents a suitable monitoring approach based on a sensory tool holder. An innovative wireless energy harvesting technology using spindle rotation is implemented. Obtained signal data for exemplary milling processes as well as corresponding signal analysis strategies are presented. © 2023 Elsevier B.V.. All rights reserved.

关键词： Cutting tools

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Intelligent dressing for continuous generating grinding with convolutional neural networks and knowledge distillation 17

Intelligent dressing for continuous generating grinding with...

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17th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2023

作者： Boesler, Martin Schumann, Marco Klimant, Philipp Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 Chemnitz09126 Germany

Continuous generating grinding is a highly productive and precise way to finish hardened gears. However, the dressing of the tool has a huge potential for optimization. Detecting the optimal point to stop the dressing process would save cost and reduce machine downtime. This paper provides a proof of concept of how machine learning models can achieve these goals based on acoustic emission data. Therefore, different ML-Classifiers were trained and compared. Particular emphasis was placed on the robustness of the models. In addition, the trade-off between fast and robust models was examined. © 2024 Elsevier B.V.. All rights reserved.

关键词： Convolutional neural networks

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