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A novel hybrid clamping system for sheet metals and thin walled structures

Procedia Manufacturing 2019年 40卷 51-55页

作者： Uwe Teicher Sebastian Pirl Andreas Nestler Arvid Hellmich Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden 01187 Germany Technische Universität Dresden Institute of Manufacturing Technology Dresden 01062 Germany Technische Universität Dresden Institute of Mechatronic Engineering Dresden 01062 Germany

Thin sheets and thin-walled structures are of great economic importance in the aerospace industry due to the enormous efforts being made in lightweight construction. The challenge in machining is to use a reliable clamping device to take account of the sheet metal or component structure as well as to work productively and reliably. For this purpose, a hybrid clamping system has been developed that functions on the basis of vacuum and the adhesive properties of a carrier medium in order to form a complex joining. This method was verified by material tests and then developed to make it usable for the HSC and HPC milling of aluminum sheets. For this purpose, demonstrator parts were manufactured in order to test the critical loads of this clamping system on the one hand and to produce structures that cannot be realized economically with other machining methods on the other hand.

关键词： clamping fixture machining sheet metal aluminum

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Process-oriented Flow Curve Determination at Mechanical Joining

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Procedia Manufacturing 2020年 47卷 368-374页

作者： Mathias Jäckel Sam Coppieters Nelis Vandermeiren Christian Kraus Welf-Guntram Drossel Noa Miyake Toshihiko Kuwabara Klaus Unruh Heinrich Traphöner A. Erman Tekkaya Tudor Balan Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden 01187 Germany KU Leuven Technology Campus Ghent Department of Materials Engineering Gebroeders De Smetstraat 1 Ghent 9000 Belgium Belgium Welding Institute Technologiepark 48 Ghent 9052 Belgium Institute of Engineering Tokyo University of Agriculture and Technology 3 Chome-8-1 Harumicho Tokyo 183-8538 Japan Faurecia Autositze GmbH Nordsehler Straße 38 Stadthagen 31655 Germany Institute of Forming Technology and Lightweight Components TU Dortmund Baroper Straße 303 Dortmund 44227 Germany Arts et Metiers Institute of Technology Université de Lorraine LCFC HESAM Université F-57070 Metz France

The accuracy of numerical simulation models for forming processes depends highly on the method for the flow curve determination. Numerous experimental tests exist to identify the flow curves of sheet metals, each with certain characteristics regarding stress states and achievable strains. In this paper stress state analysis are presented for the mechanical joining techniques clinching as well as self-pierce riveting with semi-tubular rivet (SPR). Based on these findings flow curves for DC04 material are determined by selected experimental materials tests in order to compare the influence of the flow curve determination method on the accuracy of the process simulation models.

关键词： Mechanical Joining Material Chracterization Numerical Simulation

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Incremental sheet metal forming on the example of car exterior skin parts

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Procedia Manufacturing 2019年 29卷 105-111页

作者： Sören Scheffler Alexander Pierer Peter Scholz Sebastian Melzer Dieter Weise Zdeněk Rambousek Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany VÚTS a.s. Svárovská 619 Liberec XI-Růžodol I 460 01 Liberec Czech Republic

In this article, current, application-related investigations in the field of incremental sheet metal forming (ISF) will be presented and discussed. The main focus of the study will be on the chain of conceptual design, experimentation and subsequent work processes, right through to the final assembly of car exterior skin parts of a streamlined vintage concept car. This will be accompanied by a comparison and evaluation of different production technologies with regard to their economic efficiency, their real duration times and the specific boundary conditions for the manufacturing of just one part per geometry. The manufacturing processes at the centre of the study were: deep drawing, hydroforming and ISF (Two Point Incremental forming (TPIF) and rolling). Following the holistic discussion on the procedure and choice of processes, the TPIF is examined in detail using the example of the rear mudguards.

关键词： Incremental Sheet Metal forming Two Point Incremental forming Sheet Metal forming forming machine Design

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Wishbone made of hybrid aluminum foam sandwich

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Lightweight Design worldwide 2018年第2期11卷 36-41页

作者： Claudia Drebenstedt Camilo Zopp Alexander Hackert Lothar Kroll Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany TU Chemnitz Germany

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Investigating the potential of electrical discharge machining for antibacterial coating of titanium implants 18

Investigating the potential of electrical discharge machinin...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Bui, Viet D. Mwangi, James W. Berger, Thomas Schubert, Andreas Technische Universität Chemnitz Prof. Micromanufacturing Technology Reichenhainer Strasse 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 Chemnitz09126 Germany

ISBN: (纸本)9780995775121

Titanium and titanium alloys are some of the best materials for medical implants owing to their excellent properties including biocompatibility, corrosion resistance and high fatigue strength among others. However, many implants have to be removed after implantation because of bacterial infection. Coating titanium implants with copper or silver has demonstrated antibacterial abilities and has therefore been widely applied to solve this problem. Ion implantation, physical vapour deposition, magnetron sputtering and many other different methods are used to coat these materials. However, until now, there is no method that allows for concurrent machining and coating of the antibacterial layer. Electrical Discharge Machining (EDM) has demonstrated its potential on surface modification owing to the fact that the material from tool electrode and/or powder mixed in dielectric fluid is implanted on the workpiece thereby changing its characteristics. In this study, the suitability of EDM for coating copper and silver on titanium alloy is investigated. Titanium alloy samples are machined using a high precision EDM machine and later analysed for surface quality and chemical composition. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Titanium alloys

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Product Flexible Car Body Fixtures with Position-dependent Load Balancing Based on Finite Element Method in Combination with Methods of Artificial Intelligence

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Procedia CIRP 2018年 67卷 452-457页

作者： Rayk Fritzsche Andreas Richter Matthias Putz Head of group assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strae 88 Chemnitz 09126 Germany Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strae 88 Chemnitz 09126 Germany

In car-body production, the fixtures used for fixing the car-body panels during the joining processes predominantly consist of rigid constructions that are precise and specific for one car-model. In addition to the already presented automatic adaptation of such fixtures, and specific for the production of many different car-models using same fixture, different clamping robots have been developed. In order to meet the high quality requirements, the positional deviations of these clamping robots are adjusted due to different external loads. This control loop is carried out using a combination of finite element method, mathematical algorithms and modern methods of artificial intelligence.

关键词： Quality management Body in white Rramp up Artificial intelligence Neuronal network Database

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Methodology and model for predicting energy consumption in manufacturing at multiple scales

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Procedia Manufacturing 2018年 21卷 694-701页

作者： Jan Reimann Ken Wenzel Marko Friedemann Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

Certain fields of manufacturing, like casting, forming or cutting, may cause high energy load. Especially under the consideration of renewable energy sources it is beneficial to negotiate production schedules and consumption forecasts with the energy supplier. This would enable an optimized management of energy sources and infrastructure components on the supplier side, helping to reduce costs. Optimal and balanced expenses for production would be the consequence. The problem of power consumption prediction in manufacturing was subject of many studies in the past. Most of them either consider the physical modeling of processes at a very detailed level, or they introduce tailored prediction models for specific production processes. Thus, it is hard to apply their results to other uses cases in different scenarios. As a consequence, a generic methodology and model regarding power consumption prediction in manufacturing is required in order to cover the variety of processes, machines and materials. Furthermore, an approach must support flexible levels of granularity for predicting the energy consumption of manufacturing processes. On the one hand, a whole factory may be the object of investigation while, on the other hand, predictions for finer-grained levels, such as certain parts of a machine, are required to allow for specific optimizations. Our contribution is twofold. First, we propose a generic model for the specification of the power-consuming machine. A tree-based compositional approach supports arbitrary levels, depending on the structure of the machine, or external factors, such as company policies. This approach is highly extensible since the models are stored in ontologies. Second, we propose a methodology for static and dynamic modeling of power consumption for every structural level. Based on that model the prediction can be realized. In addition, we provide an example implementation and prediction for a continuous casting machine process.

关键词： Energy efficiency Predictive Model Ontology

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Decision Support for Planning Techniques in Energy Efficiency Projects

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Procedia CIRP 2018年 69卷 306-311页

作者： Marian Süße Johannes Stoldt Andreas Schlegel Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

Factory operators can select from a multitude of measures to improve their energy efficiency. Despite the variety of planning techniques intended to help investigating the energy flows, little assistance is available for determining the most efficient approach to pursue in a specific project. This paper presents decision support procedures for making appropriate selections during planning, focusing on the selections of an energy model and a matching energy data acquisition method. They build on problem-independent decision models and systematize available alternatives. The models are solved independently by applying the Analytic Hierarchy Process that allows the integration and quantification of different criteria.

关键词： Energy efficiency Sustainable development Decision-making Analytic Hierarchy Process

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Structural loading of cellular metals: Damage mechanisms and standardization concepts 10th

Structural loading of cellular metals: Damage mechanisms and...

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10th International Conference on Porous Metals and Metallic Foams, MetFoam 2017

作者： Krupp, Ulrich Hipke, Thomas Nesic, Srecko Institute of Materials Design and Structural Integrity University of Applied Sciences Osnabrück Osnabrück49009 Germany Fraunhofer Institute of Machine Tools and Forming Technology IWU Chemnitz09126 Germany

ISBN: (纸本)9783035712315

Structural loading of cellular metals is strongly affected by brittle fracture of cell struts and walls that exhibit tensile loads, e.g., during fatigue loading. The present paper summarizes results of compression, tension and cyclic loading experiments on various closed-cell metal foams and metal foam sandwiches (Alulight, Alporas, Foamtech, AFS) using various mechanical testing systems. The results were correlated with a thorough analysis of the cellular mesostructure and the cell strut/wall microstructure by means of scanning electron microscopy revealing defects, such as casting porosity and large Si precipitates in the Al-Si eutectic of aluminum cast alloy. The results of the work served for the definition of testing standards for compression testing (ISO 13314) and tensile testing (DIN 50099), which are outlined in the paper. Such standards and design guidelines are crucial for a successful implementation of cellular metals in innovative products in mechanical, automotive and energy engineering as well as in bioengineering. © 2018 Trans Tech Publications, Switzerland.

关键词： Tensile testing

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Smart components by additive technologies

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IOP Conference Series: Materials Science and Engineering 2019年第1期480卷

作者： I Dani Fraunhofer Institute for Machine Tools and Forming Technology Germany

Smart components are key technologies for industry 4.0 as well as the Internet of Things. The application areas include e.g. systems for sustainable production, automotive, smart agriculture, and smart home. In order to integrate intelligence within a component, a sensor or actuator system typically needs to be embedded within the component itself during fabrication. Additive manufacturing has been extended to more and more industries and is now being used not only in toolmaking, but also in the series production of components. Geometric functionalization for conformal cooling is already state of the art in tool making. Despite the great potential of function-integrated parts, publications on sensor integration into parts fabricated by additive manufacturing are still rarely found. First approaches address multimaterial printing by using insulating and conductive materials as well as the integration of smart elements during the printing process. Laser beam melting (LBM) is an additive manufacturing technology for geometrically complex parts based on the layer wise and selective melting of metal powders. As proof-of-concept of the developed integration concept, based on LBM, the functionalization of tools and medical implants will be presented.

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