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International Electric Drives Production Conference (EDPC)

作者： Philipp Fiedler Sebastian Stelzer Nikolaus Milaev Robert Richter Frank Kaulfuß Thomas Windisch Jan Bräunig Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany 3D-Printpetrol Großenhain Germany Fraunhofer Institute for Material and Beam Technology IWS Dresden Germany Division Engineering of Adaptive Systems Fraunhofer IIS/EAS Fraunhofer Institute for Integrated Circuits Dresden Germany

ISBN: (数字)9781728184586

ISBN: (纸本)9781728196145

The paper addresses the prototypical development and implementation of an innovative and functionally integrated gear stage for next-generation electric vehicles, produced by using Laser Beam Melting (LBM) and Fused Deposition Modeling (FDM). Two new design targets are addressed by our approach: Oil-free operation is achieved by innovative coating of gear teeth which enables almost maintenance-free operation. Furthermore, a higher damping of sound transmission from tooth mesh to bearings is implemented by an optimal wheel body geometry that is realized by a combination of printable carbon-containing polymers (flange) and steel (gear rim). The innovative approach is to extend components by areas that cannot be produced by milling and casting, e.g. complex structures, contour-following fluid-carrying cooling elements by means of LBM, thus creating a significant benefit compared to state-of-the-art gearboxes. Function integration made possible by additive manufacturing results in a very high component complexity. It is combined with gear grinding and final ta-C coatings ensuring maximum efficiency in dry operation, to achieve economically viable production processes. The increase in tooth mesh efficiency is achieved by optimization approaches in the design to minimize heat losses while at the same time maintaining highest possible strength and lowest noise emission.

关键词： Gears Wheels Production Three-dimensional printing Laser beams Coatings Next generation networking

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The development of a digital twin for machining processes for the application in aerospace industry

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Procedia CIRP 2020年 93卷 1399-1404页

作者： Albrecht Hänel Thorben Schnellhardt Eric Wenkler Andreas Nestler Alexander Brosius Christian Corinth Alexander Fay Steffen Ihlenfeldt Institute of Manufacturing Technology Technische Universität Dresden 01062 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU 01187 Dresden Germany Institute of Mechatronic Engineering Technische Universität Dresden 01062 Dresden Germany Institute of Automation Technology Helmut Schmidt University 22043 Hamburg Germany

This paper describes a method for creating a digital twin based on planning and process data for machining processes by using the example of components in the aerospace industry. This development is based on an information model that combines the properties and relationships of relevant information and data involved in the manufacturing process. This system integrates mathematical (technical-technological) models and algorithms for the determination of process parameters as well as planning-relevant information from the machining process. The technology of the digital twin makes it possible to recognize problems directly in the machining process, e.g. deviations from the planning specifications and to derive targeted measures for quality assurance and optimization of the machining process.

关键词： digital twin machining process information model process data aerospace

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Implementation of the machine Tool-Specific Current and Voltage Control Characteristics in Multiphysics Simulation of Electrochemical Precision Machining

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Procedia CIRP 2019年 82卷 237-242页

作者： Ingo Schaarschmidt Matthias Hackert-Oschätzchen Gunnar Meichsner Mike Zinecker Andreas Schubert Professorship Micromanufacturing Technology Chemnitz University of Technology 09107 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany

In this study a multiphysics simulation model of the pulsed electrochemical machining (PECM) with oscillating cathode is shown. The focus of this study is on the implementation of machine tool-specific control characteristics in combination with physical phenomena and material removal. As a result, the implementation of the machine tool control characteristics leads to an increase of simulation accuracy of the multiphysics model. The simulation results are compared with results of previous simulations and experimental investigations.

关键词： Electrochemical machining (ECM) Material removal High strength steel

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Revisiting machinability assessment: Towards total machining performance

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CIRP Annals 2025年

作者： Jawahir, I.S. Attia, Helmi Dix, Martin Ghadbeigi, Hassan Liao, Zhirong Schoop, Julius Shokrani, Alborz University of Kentucky LexingtonKY United States Mechanical Engineering Department McGill University/Aerospace Manufacturing Technology Centre National Research Council Canada MontrealQC Canada Fraunhofer Institute for Machine Tools and Forming Technology IWU University of Technology Chemnitz Chemnitz Germany School of Mechanical Aerospace and Civil Engineering University of Sheffield Sheffield United Kingdom Faculty of Engineering University of Nottingham Nottingham United Kingdom Department of Mechanical Engineering University of Bath Bath United Kingdom

The term "machinability", introduced over hundred years ago, is vague and cannot fully describe the performance of machining systems. Machinability databases established over many decades are outdated: missing recent advances, e.g., cutting tool grades, geometry, coatings, and cutting fluids effects. This keynote paper summarizes findings of a CIRP-sponsored three-year collaborative study in five interrelated topics. The paper presents a critical review of the state-of-the-art on these topics, the results of two major round robin tests, three industry-based case studies, and a novel predictive system of machining performance, utilizing advanced deep learning methods. Outlook and future directions are also presented. © 2025 CIRP

关键词： Drills

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Non-cuttable material created through local resonance and strain rate effects (vol 10, 11539, 2020)

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SCIENTIFIC REPORTS 2020年第1期10卷 1-24页

作者： Szyniszewski, Stefan Vogel, Rene Bittner, Florian Jakubczyk, Ewa Anderson, Miranda Pelacci, Manuel Chinedu, Ajoku Endres, Hans-Josef Hipke, Thomas Durham University Durham United Kingdom Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Fraunhofer Institute for Wood Research Wilhelm-Klauditz-Institut WKI Hannover Germany Leibniz University Hannover Institute of Plastics and Circular Economy IKK Garbsen Germany University of Surrey Guildford United Kingdom University of Stirling Stirling United Kingdom

An amendment to this paper has been published and can be accessed via a link at the top of the paper.

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Hololens AR - Using Vuforia-Based Marker Tracking Together with Text Recognition in an Assembly Scenario

Hololens AR - Using Vuforia-Based Marker Tracking Together w...

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IEEE International Symposium on Mixed and Augmented Reality Workshops (ISMARW)

作者： Sebastian Knopp Philipp Klimant Robert Schaffrath Eric Voigt Rayk Fritzsche Christoph Allmacher Institute for Machine Tools and Production Processes Chemnitz University of Technology Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz University of Technology Chemnitz Germany

ISBN: (纸本)9781728147666

Many real world applications for Microsoft HoloLens*-based applications suffer the problem of reliably recognizing and identifying movable objects within an environment. While the HoloLens is perfectly able to discern already known rooms, it still has troubles with reflecting surfaces or identically shaped objects. Using dedicated recognition libraries for each task poses the issue of shared resource access in the rather controlled HoloLens environment-In this poster we present a solution for scenario with hard to track objects and similarly shaped objects for an electrical cabinet assembly task, where the reflective cabinet is tagged with a marker and the prefabricated cables are differentiated by text-based labels.

关键词： HoloLens AR Vuforia Text recognition Application showcase Printed text recognition Argon Posters Cabinets Cabinet

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Method for Capacity Planning of Changeable Production Systems in the Electric Drives Production

Method for Capacity Planning of Changeable Production System...

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International Electric Drives Production Conference (EDPC)

作者： Jens Niemann Andreas Schlegel Matthias Putz BMW AG Munich Germany Machine Tools Production Systems and Machining Fraunhofer-Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (数字)9781728143194

ISBN: (纸本)9781728143200

Market growth and technological uncertainties characterize the electro-mobility. High emission standards, fossil fuel scarcity, environmental protection, and political initiatives promote this development. Besides, factors such as customer behavior, infrastructure, new competitors, and technological developments induce high volatility in forecasted market volumes. Due to these uncertainties, production systems of electrified vehicles require a combination of changeable production systems and flexibility measures. The production capacity of changeable production systems is currently determined by a conventional capacity planning method, which does not integrate the degrees of freedom conferred by changeability. In this publication, we present a new capacity planning method of changeable production systems in electro-mobility. Changeability comprises pre-defined measures that change either the capacity or the technological spectrum of productions by an investment. A total of five changeability drivers exist, thereof we consider scalability and universality. Scalability in this context refers to the technical, local, and personnel possibilities to expand and reduce factory elements and production systems. Universality focuses on technological production properties, in particular, the ability to meet different production and technology requirements. We define specific changeability options for both drivers. Moreover, we integrate these in production capacity planning, which leads to various production configurations. Additionally, we evaluate the monetary impact and the resulting flexibility of each configuration at any time within the observation period using the real options approach. We choose this approach to integrate market uncertainties in the decision- making process. Further, a Monte Carlo simulation validates all configurations showing positive option values, and we determine a final capacity plan. We apply the method to a production system for electric drives

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High-Speed Incremental forming – New Technologies For Flexible Production Of Sheet Metal Parts

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Procedia Manufacturing 2019年 27卷 21-26页

作者： M. Linnemann V. Psyk E. Djakow R. Springer W. Homberg D. Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz Germany Paderborn University – Department of Forming and Machining Technology Pohlweg 47-49 33098 Paderborn Germany

High-speed forming technologies have a very high potential for shaping complex parts and constitute a key means of reducing a component’s weight. For many materials they offer advantages such as low tool cost, high tool flexibility and extended forming limits at room temperature,. Hence, stringent emission regulations can be fulfilled and essential resources are saved. The limited forming zone, however, makes it impossible to achieve flexible, cost-efficient production of complex large-surface parts by high-speed forming alone. In order to overcome this problem, this paper suggests two different innovative forming concepts which enhance the pulsed-power-driven, high-speed forming technologies of electrohydraulic forming and electromagnetic forming by applying an incremental strategy. The concept is presented for both technologies, with a description of the different setups required for achieving the incremental movement in the forming sequence, employing guide railsand an industrial robot. Advantages and limits are discussed, and first experimental results prove the feasibility and give an impression of the process potential.

关键词： Incremental Sheet forming Electromagnetic forming Hydroforming

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Kinematics of the Lumbo-Pelvic Complex under Different Loading Conditions

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Current Directions in Biomedical Engineering 2019年第1期5卷 347-349页

作者： Weidling, Martin Voigt, Christian Wendler, Toni Heilemann, Martin Werner, Michael Jarvers, Jan-Sven Heyde, Christoph-E. Center for Research on Musculoskeletal Systems (ZESBO) Faculty of Medicine University of Leipzig Semmelweisstrasse 14 Leipzig Germany Center for Research on Musculoskeletal Systems (ZESBO) Faculty of Medicine University of Leipzig Leipzig Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Department of Orthopaedic Trauma and Plastic Surgery University Hospital Leipzig Leipzig Germany

The lumbo-pelvic complex is a highly complex structural system. The current investigation aims to identify the kinematics between interacting bone segments under different loading conditions. A specimen of the lumbo-pelvic complex was obtained from a human body donor and tested in a self-developed test rig. The experimental setup was designed to imitate extension, flexion, right and left lateral bending and axial rotation to the left and to the right, respectively. The vertebra L3 was firmly embedded and load was introduced via hip joints. Using a digital image correlation (DIC) system, the 3D motions of 15 markers at different landmarks were measured for each loadcase under cyclic loading. For each loadcase, the kinematics were analyzed in terms of three-dimensional relative movements between L3 and the sacrum. The usefulness of the experimental technique was demonstrated. It may serve for further biomechanical investigations of relative motion of sacroiliac and vertebral joints and deformation of bony structures. © 2019 by Walter de Gruyter Berlin/Boston.

关键词： Kinematics

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Tool System for UV induced micro moulding of biomedical disposables 18

Tool System for UV induced micro moulding of biomedical disp...

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

作者： Edelmann, J. Gärtner, E. Eckert, U. Griebel, J. Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Leibnitz IOM Leipzig Germany

ISBN: (纸本)9780995775121

A new approach for the generation of double-sided microstructured polymer films is presented based on injection-molding of urethane- and epoxy-based acrylates that are polymerized by irradiation with ultraviolet light (395 nm). Compared to hot embossing, this offers not only working under ambient conditions, but also a reduction of cycle time as well as flexibility regarding adjustment of the mechanical and/or chemical properties of the resulting polyacrylate film. A setup, consisting of the mold with the microstructured insert and two LED lamps emitting UV-light moved by a controllable stepper motor and a computer-based controller, was installed and successfully used for the fabrication of double-sided microstructured polyacrylate films. Therefore a new and innovative tool system for 2-component UV induced micro moulding of biomedical disposables was developed. The geometrical dimensions of the microstructures (e.g. fins, channels, sharp edges and slopes) require different technologies to machine the tool inserts. Therefore micromilling and μ-laserablation technologies were used in combination attached by laser polishing operations in special areas. A highly precise, complex designed tool system with mechanically moveable areas is needed to fill the tool with the 2 various chemical compositions. The paper presents the tool concept and explains the investigated surface treatment options. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Micromachining

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