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Flushing Strategies for High Performance, Efficient and Environmentally Friendly Cutting

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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Multiphysics Simulation of the Material Removal in Jet Electrochemical Machining

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Procedia CIRP 2015年 31卷 197-202页

作者： Matthias Hackert-Oschätzchen Raphael Paul Michael Kowalick André Martin Gunnar Meichsner Andreas Schubert Professorship Micromanufacturing Technology Faculty of Mechanical Engineering Technische Universität Chemnitz D-09107 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 D-09126 Chemnitz Germany

Jet Electrochemical Machining (Jet-ECM) is a technology for quickly and flexibly generating micro structures and micro geometries in metallic parts independently from the material's hardness and without any thermal or mechanical impact [1] . In the process no tool wear occurs and the machined surface is very smooth [2] . The Jet-ECM process strongly depends on the shape of the electrolyte jet. In a previous study Hackert [3] built a numerical model with COMSOL Multiphysics based on a predefined jet shape. The simulated dissolution results of this model progressively differ from experimental results with increasing processing time. Hence, a multiphysics model which integrated fluid dynamics using the level set method for two-phase flow was created. Furthermore, in the present study the electric boundary resistance at the interface of workpiece and electrolyte is considered. According to the real Jet-ECM process the simulation is divided into two steps. In the first simulation step the jet is formed, and in the second simulation step the anodic dissolution is simulated by deforming the geometry. The dynamic behavior of the electrolyte jet could be simulated during the material removal process. So effects became visible which affect the machining results.

关键词： Jet Electrochemical Machining localized anodic dissolution continuous electrolytic free jet multiphysics simulation boundary resistance

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Making Sustainability Paradigms a Part of PPC

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Procedia CIRP 2015年 29卷 209-214页

作者： Matthias Putz Johannes Stoldt Christin Fanghänel Annett Bierer Andreas Schlegel Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz Germany HTWK Leipzig – Faculty of Business Administration Gustav-Freytag-Straße 42a04277 Leipzig Germany

The mounting pressure of the European legislative to improve the sustainability of production operations prompts companies to implement sustainability paradigms into their production planning and control (PPC). First results from an ongoing European project will show how the innovative Resource Networks Methodology can be used to alter the production organisation accordingly. In particular, novel PPC strategies improving the integration of renewable energy sources and other resource efficient technologies by using previously identified levels of flexibility will be presented. These are complemented by an approach for unifying the readiness levels for application (RLA) of similar methodologies. The latter will assist decision making during the development phase and in preparation for industrial implementations.

关键词： Production planning Sustainable development Readiness levels Resource networks

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Manufacturing of micro fluidic moulds by combining micro milling and laser structuring 14

Manufacturing of micro fluidic moulds by combining micro mil...

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14th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2014

作者： Schubert, A. Gross, S. Eckert, U. Edelmann, J. Fraunhofer Institute for Machine Tools and Forming Technology IWU Germany

ISBN: (纸本)9780956679031

Increasing demands regarding the functionality and the functional density of micro fluidic systems require constant miniaturisation of single components and also of the complete system. A cost efficient and effective manufacturing process requires replication processes such as injection moulding or hot embossing to structure disposables cost-effectively. This paper presents the development of the sequential process combination of laser micro structuring and micro milling for the manufacturing of micro fluidic moulds.

关键词： Injection molding

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Evaluating mobile machine tool dynamics by substructure synthesis

Evaluating mobile machine tool dynamics by substructure synt...

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WGP Congress 2014

作者： Law, Mohit Rentzsch, Hendrik Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (纸本)9783038352457

Mobile machining solutions use autonomous machining units that can be transported to different part locations, making possible easy maintenance and repair of large industrial equipment. Every new part and location results in different boundary conditions for the mobile machine toolpart system, influencing the dynamics of the combined system and necessitating different strategies for part/machine referencing and clamping. To facilitate efficient mutability and modularity in mobile machining solutions, this paper presents a dynamic substructuring strategy that combines the response characteristics of the mobile machine unit with that of two different simulated base models under varying levels of contact stiffness and damping to obtain the synthesized mobile machine tool dynamic response. Numerical verification of the approach is provided. The framework presented can also combine measured response of parts for which models may not be available a priori. Methods presented provide experimental guidelines for establishing strategies for part/machine referencing and planning of machining strategies based on the esaluated dynamics. © (2014) Trans Tech Publications, Switzerland.

关键词： Dynamics

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Development of Patient-specific Orbital Floor Implants Made of Shape Memory Alloys

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Procedia CIRP 2016年 49卷 143-146页

作者： Ronny Grunert Jürgen Lichtenstein Nicole Preßler Matthias Geßner Christian Rotsch Maximilian Wagner Susanna Posern Friedemann Pabst Welf-Guntram Drossel Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 01187 Dresden Germany Universitätsklinikum Leipzig Klinik und Poliklinik für Orthopädie Unfallchirurgie und Plastische Chirurgie Liebigstraße 20 04103 Leipzig Germany Medizinische Hochschule Hannover Klinik und Poliklinik für Mund- Kiefer- und Gesichtschirurgie Carl-Neubergstraße 1 30625 Hannover Germany Krankenhaus Dresden Friedrichstadt Klinik für Hals-Nasen-Ohrenheilkunde Kopf- und Hals-Chirurgie Plastische Operationen Friedrichstraße 41 01067 Dresden Germany

The shape memory alloy NiTi has successfully proved in many areas of medical technology. This paper describes the innovative idea and development of orbital floor implants made of NiTi. Pseudoelastic NiTi has the peculiarity to withstand large mechanical deformations of up to 8% without being plastically deformed, i.e. it returns to its original shape with relief of the strain. This material property can be used to produce flexible, yet stable implants. The NiTi implants can be implanted into the body in compressed form through relatively small approaches. Arriving at the fracture position, they develop self-reliantly in the previously memorized shape. The perioperative trauma is reduced. The treatment of orbital floor fractures is often done surgically by use of implants made of rigid materials such as titanium, which are inserted in the eye socket through an open approach on the lower eyelid. Implants made of a pseudoelastic shape memory alloys can help to reduce the required incision length of the approach. It is even possible to insert the implant in a minimally invasive procedure via endoscopic access routes and to completely avoid open approach. In this paper first design variants of pseudoelastic orbital floor implants are presented and considerations on the manufacturing process are made.

关键词： NiTi orbital floor fracture orbital reconstruction patient-specific implants shape memory alloys

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Tailoring properties of commercially pure titanium by gradation extrusion

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AIP Conference Proceedings 2016年第1期1769卷

作者： Markus Bergmann Anja Rautenstrauch René Selbmann Raoni Barreto de Oliveira Rodrigo Santiago Coelho Dirk Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Technische Universität Chemnitz Institute of Machine Tools and Production Processes IWP Reichenhainer Straße 70 09126 Chemnitz Germany SENAI Cimatec Av. Orlando Gomes 1845 – Piatã 41650-010 – Salvador Brazil

Commercially pure titanium (CP Ti) is of great importance in medical applications due to its attractive properties, such as high biocompatibility, excellent corrosion resistance and relatively low density and suitable stiffness. Compared to the commonly used Ti-6Al-4V alloy, its lower strength has to be increased. The most attractive approach is to subject CP Ti to severe plastic deformation (SPD) processes such as Equal Channel Angular Pressing (ECAP). The resulting decreased grain size in CP Ti yields a significant increase in hardness and strength. Common SPD-processes typically provide a uniform modification of the material. Their material efficiency and productivity are critical and limiting factors. A new approach is to tailor the material properties by using Gradation Extrusion, which produces a distinct gradient in microstructure and strength. The forming process combines a regular impact extrusion process and severe plastic deformation in the lateral area of the material. This efficient process can be integrated easily into forming process chains, for instance for dental implants. This paper presents the forming process and the applied die geometry. The results of numerical simulations are used to illustrate the potential of the process to modify and strengthen the titanium material. Experiments show that the material is successfully processed by gradation extrusion. By characterizing the hardness and its distribution within the formed parts the effects of the process are investigated.

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A novel tool design strategy for electromagnetic forming

A novel tool design strategy for electromagnetic forming

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WGP Congress 2014

作者： Neugebauer, Reimund Psyk, Verena Scheffler, Christian Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 Chemnitz Germany

ISBN: (纸本)9783038352457

To make the advantages of electromagnetic forming applicable for industrial manufacturing, a three step tool design strategy is suggested. At first, simplified decoupled electromagnetic and structural mechanical simulations are used for creating a preliminary design via a systematic iterative optimization process. The selected design is verified in more accurate coupled simulations. A prototypic realization serves for further optimization, if necessary. The applicability of the approach is proved on the basis of an inductor system for magnetic pulse welding of tubes. © (2014) Trans Tech Publications, Switzerland.

关键词： Metal forming

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The suitability of analytical and numerical methods for developing clinching processes with thick sheet metal

The suitability of analytical and numerical methods for deve...

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WGP Congress 2012

作者： Israel, Markus Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

ISBN: (纸本)9783038350538

At present, the use of clinching is mainly restricted to thin sheet metal. Here the joining technology is used for assemblies in mass production due to its great coast efficiency. However, the branches of industry working with thick sheet metal (utility and rail vehicle engineering, shipbuilding and general structural steel engineering) represent a major potential for using clinching technology. Unfortunately, the suitability of clinching for connecting jobs with substantially greater sheet metal thicknesses has neither been sufficiently investigated, nor are there suitable toolsets among system manufacturers that are adapted to the larger overall sheet metal thicknesses. Instead, the state-of-the-art for ascertaining tools for larger sheet metal thicknesses and point dimensions is trial and error accepting the high costs caused by producing a large number of tools and experiments. This paper demonstrates some analytical approaches to this problem and how suitable they are to describing the process of clinching in comparison to the potential of calculation with FEA. © (2014) Trans Tech Publications, Switzerland.

关键词： Sheet metal

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Effect of new adhesion promoter and mechanical interlocking on bonding strength in metal-polymer composites

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IOP Conference Series: Materials Science and Engineering 2016年第1期118卷

作者： A Schuberth M Göring T Lindner G Töberling M Puschmann F Riedel I Scharf K Schreiter S Spange T Lampke Materials and Surface Engineering Group Institute of Materials Science and Engineering Technische Universität Chemnitz 09125 Chemnitz Germany Polymer Chemistry Technische Universität Chemnitz 09111 Chemnitz Germany Department of Joining and assembling Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany

There are various opportunities to improve the adhesion between polymer and metal in metal-plastic composites. The addition of a bonding agent which reacts with both joining components at the interfaces of the composite can enhance the bonding strength. An alternative method for the adjustment of interfaces in metal-plastic composites is the specific surface structuring of the joining partners in order to exploit the mechanical interlock effect. In this study the potential of using an adhesion promoter based on twin polymerization for metal-plastic composites in combination with different methods of mechanical surface treatment is evaluated by using the tensile shear test. It is shown that the new adhesion promoter has a major effect when applied on smooth metal surfaces. A combination of both mechanical and chemical surface treatment of the metal part is mostly just as effective as the application of only one of these surface treatment methods.

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