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The effect of cushion-ram pulsation on hot stamping

AIP Conference Proceedings 2016年第1期1769卷

作者： Dirk Landgrebe Anja Rautenstrauch Andreas Kunke Stefan Polster Sebastian Kriechenbauer Reinhard Mauermann 1Technische Universität Chemnitz Professorship for Forming and Joining Germany 2Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

Hot stamping is an important technology for manufacturing high-strength components. This technology offers the possibility to achieve significant weight reductions. In this study, cushion-ram pulsation (CRP), a new technology for hot stamping on servo-screw presses, was investigated and applied for hot stamping. Compared to a conventional process, the tests yielded a significantly higher drawing depth. In this paper, the CRP technology and the first test results with hot stamping were described in comparison to the conventional process.

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Approaches for mechanical joining of 7xxx series aluminum alloys

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AIP Conference Proceedings 2016年第1期1769卷

作者： M. Jäckel T. Grimm D. Landgrebe 1Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 01187 Dresden Germany

This paper shows a numerical and experimental analysis of the different problems occurring during or after the conventional self-pierce riveting with semi-tubular and solid rivets of the high strength aluminum alloy EN AW-7021 T4. Furthermore this paper describes different pre-process methods by which the fracture in the high strength aluminum, caused by the self-pierce riveting processes, can be prevented and proper joining results are achieved. On this basis, the different approaches are compared regarding joint strength.

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The application of double-layer capacitor modules for energy storage devices in production machinery

The application of double-layer capacitor modules for energy...

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European Conference on Power Electronics and Applications

作者： Matthias Putz Artem Kolesnikov Mark Richter Thomas Koch FRAUNHOFER INSTITUTE FOR MACHINE TOOLS AND FORMING TECHNOLOGY 09126 Reichenhainer Str. 88 Chemnitz Germany

ISBN: (纸本)9781479982776

The development approach for an energy storage system focuses on optimal sized double-layer capacitor modules to reduce peak power and to avoid malfunctions of production machinery caused by voltage interruptions. The required kind of charging for the energy storage system and adjustment of voltage control parameters was executed for line-side converters of drive groups in production machinery. The energy efficiency of electric drives with and without such an energy storage system was investigated by means of active power measurements and simulations of electric power flows in Matlab/SimPowerSystems.

关键词： Efficiency Energy Storage Supercapacitor machine tool drive Modelling

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Approach for Production Planning in Reconfigurable Manufacturing Systems

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Procedia CIRP 2015年 33卷 70-75页

作者： Andreas Hees Gunther Reinhart Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Project Group Resource-efficient Mechatronic Processing Machines Beim Glaspalast 5 86153 Augsburg Germany

To stay competitive and to fulfill the changing market needs, manufacturing companies have to adapt their manufacturing systems in frequent and short intervals. Hence, changeable and reconfigurable manufacturing systems (RMS) are proposed and discussed in a multitude of research publications. While production planning becomes increasingly complex in this context, it has to be reliable and quick at the same time. Therefore, the performance and flexibility of manufacturing systems depends on actual and suitable planning data with high quality and wide range. In this context, a new approach for production planning in reconfigurable manufacturing systems is exposed in this paper. Data models, a configuration management and a sequential method for the resource planning help to integrate reconfigurable manufacturing systems’ key characteristics in production planning and control (PPC). Finally a prototypical application scenario, for the evaluation and demonstration of the feasibility of the planning approach, is outlined.

关键词： Production Planning Reconfiguration Scheduling

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Analytical Modelling Methods for Temperature Fields in Metal Cutting Based on Panel Method of Fluid Mechanics

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Procedia CIRP 2015年 31卷 352-356页

作者： F. Klocke M. Brockmann S. Gierlings D. Veselovac D. Kever B. Roidl G. Schmidt U. Semmler Laboratory for Machine Tools and Production Engineering RWTH Aachen University Aachen Germany Chair of Fluid Mechanics and Institute of Aerodynamics RWTH Aachen University Aachen Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

Temperature fields and subsequent heat flow into the components chip, tool and workpiece are of major significance for metal cutting. The temperature field in the tool influences for example the type of wear and the tool life and hence the temperatures evolving in the workpiece are responsible for later product quality. However, measurements of temperature fields in metal cutting require experimental efforts and are often prone to measurement errors. The present paper describes an analytical modelling method based on potential theory. Potential functions are successfully applied in other engineering fields, i.e. fluid mechanics and electrostatics. The fact that solutions for the same class of differential equation, namely the Laplace Differential Equation, are required give rise to apply the potential theory to describe the temperature field in metal cutting processes. While first approaches of the theory were more arbitrary, the so called panel method provides a systematic method for consideration of adiabatic boundaries and heat source strengths. In particular, cutting edge geometries and cutting edge radius as well as influence of wear can be considered with this method. Note that complex geometries and non-symmetrical heat sources cannot be covered by conventional analytical models of temperature fields in metal cutting. In terms of validation the modelling outcomes are compared to infrared camera pictures, conventional analytical model outcomes (modified model from Komanduri & Hou) and FEM simulation outcomes.

关键词： Machining Modelling Temperature

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Intrinsic manufacture of hollow thermoplastic composite/metal structures

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AIP Conference Proceedings 2016年第1期1769卷

作者： Daniel Barfuss Raik Grützner Christian Garthaus Maik Gude Roland Müller Dirk Langrebe 1Technische Universität Dresden Institute of Lightweight Engineering and Polymer Technology Germany 2Fraunhofer-Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

In contrast to common and classical joining technologies for composite/metal hybrid structures such as bonding and riveting, profile and contour joints offer a promising potential for novel lightweight hybrid structures. First and foremost, joining systems with a form closure function enable to pass very high loads into rod- and tube-shaped fibre reinforced structures and achieve high degrees of material utilization for the composite part. This paper demonstrates the theoretical and technological principals for a resource efficient design and production of highly loaded thermoplastic composite profile structures with integrated metallic load introduction elements and a multi scale form closure. The hybrid structures are produced in an integral blow moulding process in which a braided tape-preform is simultaneously consolidated and formed into the metallic load introduction element. These metallic load introduction elements are manufactured in a two-stage process of external and internal hydroforming, after forming simulations have assured process stability for consistent quality.

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Tailoring of mechanical properties of a side sill part made of martensitic stainless steel by press hardening

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AIP Conference Proceedings 2016年第1期1769卷

作者： Enrique Meza-García Anja Rautenstrauch Verena Kräusel Dirk Landgrebe Technische Universitaet Chemnitz Faculty of Mechanical Engineering Institute for Machine Tools and Production Processes Professorship for forming and joining. Reichenhainer Str.70 D-09126 Chemnitz Germany Fraunhofer-Insitute for Machine Tools and Forming Technology Reichenhainer Str.88 D-09126 Chemnitz Germany

The present work deals with a technological study to integrate the 1.4034 martensitic stainless steel sheet alloy in the conventional press hardening process. Based on preliminary work, side sill demonstrators with tailored mechanical properties were manufactured by press hardening under conventional process parameters. The resulting microstructure and mechanical properties of the produced parts were characterized. The tailoring of the mechanical properties consists of the development of two sections with completely different mechanical properties in a single part. To achieve this, a half of the blank was insulated with a refractory during austenitization treatment. This avoided the heating of the insulated side until the austenitization temperature. Therefore, only the non-insulated side was hardened by quenching. Moreover, depending on the austenitization temperature the resulting mechanical properties can be adjusted.

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Flushing Strategies for High Performance, Efficient and Environmentally Friendly Cutting

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Procedia CIRP 2015年 26卷 361-366页

作者： P. Blau K. Busch M. Dix C. Hochmuth A. Stoll R. Wertheim Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Technische Universität Chemnitz Institute for Machine Tools and Production Processes IWP Reichenhainer Str.70 09126 Chemnitz Germany

The rising requirements in cutting operations for higher performance and higher efficiency respecting also environmental phenomena are influencing the use of different coolants and flushing conditions. In machining difficult-to-cut materials, in particular high-temperature materials, conventional emulsion cooling is unsuitable due to the insufficient cooling effect and the energy and cost intensive equipment required. For this reason new cooling and lubricating strategies have to be developed and investigated. Using hybrid processes, mainly by superposition of various cooling strategies, offers the potential to extend the existing technological process limits of conventional cutting processes. The paper introduces theoretical, experimental and simulation results with various innovative cooling strategies, such as high-pressure cooling, cryogenic cooling and aerosol dry lubrication in grooving, turning and drilling and derives the appropriate field of application for each flushing strategy.

关键词： Cutting Coolant Flushing HPC

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Energy-sensitive control strategies for decoupled production systems

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International Journal of Sustainable Manufacturing 2014年第3期3卷 250-268页

作者： Putz, Matthias Schlegel, Andreas Stoldt, Johannes Franz, Enrico Langer, Tino Division Production Management Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

Rising demand for energy caused by emerging economies, decreasing oil stocks, and the intended nuclear phase-out in some industrial countries has led to new problems concerning sufficient and on time energy supply. Since availability of energy has a dramatic influence on production, energy has to be considered a process prerequisite instead of a production-related overhead topic, as usually done. Prospective considerations in MES and ERP systems will need to treat energy as a limited resource just like machine capacity and time. Hence, both products and processes will compete for energy. This paper discusses selected production control tasks, methods, and strategies for discrete part manufacturing. It aims at identifying the extent to which energy features can be implemented next to established logistic goals. Based on first research activities, new approaches were derived in order to develop tools for an energy-sensitive production control focusing on limited capacity of production resources. Copyright © 2014 Inderscience Enterprises Ltd.

关键词： Production control

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Analysis of Cutting Stability in Vibration Assisted Machining Using Ananalytical Predictive Force Model

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Procedia CIRP 2015年 31卷 515-520页

作者： Yuan Gao Ronglei Sun Jürgen Leopold State Key Laboratory of Digital Manufacturing Equipment and Technology School of Mechanical Science and Technology Huazhong University of Science and Technology Wuhan430074 China Formerly Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz 09661 Germany

Vibration assisted machining (VAM)adds sinusoidal tool vibration to the conventional machining (CM) process. It is generally recognized that VAM can effectively improve machining quality and machining efficiency, however, the theoreticalbasis for this isnot fully developed. One feasible explanation is about the improvement of cutting stability. In the previous literatures, time-domain simulationsof chatter forCM and VAM have been compared, showing VAM can suppress chatter and increase cutting stability under various conditions. However, the stability lobe diagram that givesa global picture of the stability behavior is still unavailable for VAM. This paper is dedicated to draw the stability lobe diagram for VAM and compare it with that for CM. An analytical predictive force model is developed to determine the dynamic cutting forcein VAM, incorporating material properties, tool geometry, cutting conditions and vibration parameters. Then a stability analysis based on the proposed force model is done and the corresponding stability lobe diagram is obtained, which shows the effect of VAM on cutting stability on a large spindle speed scale. Finally, cutting experiments about surface roughnessare carried out to verify the theoretical conclusion.

关键词： Vibration assisted machining Conventional machining Chatter Stability lobe diagram

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