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

作者： Uhlmann, E. Polte, M. Hocke, T. Thißen, K. Bolz, R. Streckenbach, J. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

ISBN: (纸本)9781998999132

Nowadays graphite and copper are the most used tool electrode materials for electrical discharge machining (EDM). Especially for roughing operations to machine mould inserts made of steel, graphite allows high material removal rates, with high discharge energies and reduced relative tool wear. In addition, graphite is characterized by better machinability compared to copper, which leads to a cost-effective production of complex tool electrode geometries. To take advantage of the machinability and flexibility in producing complex tool electrode geometries, graphite is also used for EDM finishing. However, in EDM finishing, graphite shows still higher material removal rates but is also characterised by significantly higher relative tool wear compared to copper. This relative tool wear is fundamentally dependent on the material properties and the used process parameters. Therefore, this paper presents an approach for using graphite in EDM finishing operations. A parameter study was carried out using five different types of graphite to machine steel components. Within the investigations, different types of graphite with grain sizes in the range of 1.0 μm 11.0 %. Therefore, the experiments showed a great improvement regarding the relative tool wear for graphite. Ten additional graphite types will be used for further investigations to gain a deeper understanding of the tool wear mechanisms. This will enable the reliable and efficient application of graphite as a tool electrode material for EDM finishing. © 2023 Euspen Headquarters.

关键词： Cost effectiveness

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Toward an Efficient Industrial Implementation of W-temper forming for 7xxx Series Al Alloys 13th

Toward an Efficient Industrial Implementation of W-temper Fo...

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13th International Conference on the technology of Plasticity, ICTP 2021

作者： Trân, Ricardo Kertsch, Lukas Marx, Sebastian Hebbar, Shreyas Psyk, Verena Butz, Alexander Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Fraunhofer Institute for Mechanics of Materials IWM Wöhlerstraße 11 Freiburg79108 Germany

ISBN: (纸本)9783030753801

Manufacturing technologies for parts made from ultra-high-strength 7xxx series aluminum sheet material have been the focus of research in recent years. A promising approach is W-temper forming, where sheet material is cold formed after heat treatment. Conventional heat treatment routes are very time-consuming and inefficient. In this study, a new more efficient and industry-orientated transfer tool concept has been developed. Heating and cooling of the sheets take place in separate contact tempering stages, which allow superior heating and cooling rates in comparison to conventional methods. To analyze the influences of temperature rates and deformation on microstructure and mechanical behavior, thermo-mechanical experiments in a Gleeble simulator were carried out. The results prove the great potential of the transfer tool concept with inline heat treatment for series production. The process-dependent mechanical properties determine a suitable process window for the industrial application of the W-temper forming of the analyzed alloys. © 2021, The Minerals, Metals & Materials Society.

关键词： Industrial research

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Precise cutting of cemented carbide with nanopolycrystalline diamond in ductile regime 23

Precise cutting of cemented carbide with nanopolycrystalline...

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

作者： Uhlmann, Eckart Polte, Mitchel Hocke, Toni Polte, Casey Polte, Julian Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

ISBN: (纸本)9781998999132

Today's demands on technical applications require the precise machining of high-performance materials. Cemented carbide is used as a wear-resistant material in a wide range of industrial applications, e.g. tool and mould making, mobility and medical engineering. Due to the brittle material characteristics and the resulting high hardness and wear resistance, the machining of the cemented carbide is severely limited. Long machining times and high tool wear are remaining challenges at state of the art. A novel approach for the machining of cemented carbide is the application of binderless nanopolycrystalline diamond (NPD) as cutting material for precise turning. Based on investigated fundamental cutting phenomena, within the scope of this work, the application of the novel cutting material was further investigated by comprehensive turning experiments. Turning tests were carried out with cemented carbide samples with a tungsten carbide content of CC = 88 %, a cobalt content of CCo = 12 % and a grain size of dg = 0.5 μm. Prior to the turning tests, the brittle-ductile transition as well as the minimum chip thickness were determined by dedicated spiral cutting tests as a function of the feed. In subsequent turning tests, the influence of the cutting speed, feed velocity and depth of cut were investigated. Process forces were evaluated and specimens were analysed regarding surface roughness and topography. In the course of the investigations, it could be shown that a dedicated set of process parameters enable cutting in ductile regime with great chip formation. Thus, the great potential of the novel cutting material NPD in turning of cemented carbide could be demonstrated. © 2023 Euspen Headquarters.

关键词： Turning

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Data Acquisition Framework for spatio-temporal analysis of path-based welding applications 57

Data Acquisition Framework for spatio-temporal analysis of p...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Safronov, Georgij Theisinger, Heiko Sahlbach, Vasco Braun, Christoph Molzer, Andreas Thies, Anabelle Schuba, Christian Shirazi, Majid Reindl, Thomas Hänel, Albrecht Engelhardt, Philipp Ihlenfeldt, Steffen Mayr, Peter BMW AG Petuelring 130 München80788 Germany Technical University of Munich Materials Engineering of Additive Manufacturing Freisinger Landstraße 52 Garching bei München85748 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Nebumind GmbH Willy-Messerschmitt-Straße 1 Taufkirchen82024 Germany

The use of digital technologies in industrial manufacturing reduces operational costs and improves production quality. The "Framework for Spatiotemporal Production Data Acquisition" (PathSense) aims to improve access and usability of production data by applying a common data ecosystem. Through integrating operational technology (OT) and information technology (IT), PathSense supports decision-making and process optimization. The framework uses the concept of digital shadows to collect critical information from sensors within the continuous manufacturing processes, e.g., welding or gluing lines. Spatial and temporal digital shadows are developed in accordance with human spatial cognition to support sophisticated-yet intuitive-human-computer interactions without the need for advanced data science skills. The backbone of the framework consists of robust data pipelines with a setup incorporating modern IT protocols, such as OPC UA and MQTT, to support the efficient acquisition and management of data. The paper addresses the challenges associated with the combination of IT and OT in cyber-physical systems, stressing modern complex data-intensive manufacturing as one exemplary domain to be tackled by scalable and secure data architectures. The paper identifies two major future directions: refining data integration processes and embedding advanced machine learning algorithms to enable automated data analysis and improve process quality monitoring. In summary, PathSense proposes a data-driven approach for quality inspection in manufacturing, which may eventually enhance industry practices and move towards data-driven decisions and increased operational flexibility. © 2024 The Authors.

关键词： Spatio-temporal data

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Biointegrated cooling lubricants: Procedure model and initial testing 56

Biointegrated cooling lubricants: Procedure model and initia...

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

作者： Hagen, Johanna Arafat, Robar Schömig, Oliver Herrmann, Christoph TU Braunschweig Institute for Machine Tools and Production Technology IWF Langer Kamp 19b Braunschweig38106 Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Bienroder Weg 54E Braunschweig38108 Germany

Nowadays special attention is given to the sustainability in the machining industry. Especially consumables, such as cooling lubricants, can have a high environmental burden. These burdens are connected to all life cycle stages: (i) Raw material extraction, (ii) energy and resource use in processing, (iii) negative impact on working environment (iv) and disposal. Cooling lubricants, this also applies for water-miscible, predominantly contain fossils, requiring intensive processing for production and waste management. Furthermore, effects like the contamination by microorganisms either require the use of biocides that could affect the health of machine users or shorten the fluids overall lifetime. One possible approach to overcome these burdens comes from the field of biologicalisation, an emerging research effort to symbiotically link technosphere and biosphere. Microorganisms and algae hold potentials to be used as renewable raw materials for cooling lubricants due to their lubricating properties and the possibility of direct production in the factory. In studies, microorganism and algae strains have been dissolved in water and tested for their lubricating properties with promising results. However, there is a lack of further developments regarding the treatment of the negative effects by additives and the achievement of the quality standard of conventional cooling lubricants. A procedure model for the development of microbial lubricants and their implementation into process systems has been developed. Based on the functional requirements of current lubricants, additive substitutes are presented and their function-oriented compatibility is qualitatively evaluated. Additionally, the impact on the environment will be considered and discussed. Furthermore, new functions and requirements for this type of cooling lubricants will be evaluated, which results from the use of dead or living microorganisms. For this purpose, first laboratory tests have been carried out, conc

关键词： additives biointegration biologicalisation lubricants sustainability

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Application of Hybrid Laser Arc Welding for Construction of LNG Tanks Made of Thick Cryogenic 9% Ni Steel Plates

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Lasers in Manufacturing and Materials Processing 2023年第4期10卷 659-680页

作者： Gook, Sergej El-Batahgy, Abdel-Monem Gumenyuk, Andrey Biegler, Max Rethmeier, Michael Joining and Coating Technology Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 Berlin10587 Germany P. O.Box: 87 Helwan El-Tabbin Cairo Egypt Unter den Eichen 87 Berlin12205 Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

Hybrid laser-arc welding (HLAW) was applied for butt welding of 14.5 mm thick plates of ferritic cryogenic steel X8Ni9 containing 9% Ni, which is used for manufacturing storage and transport facilities of liquefied natural gas (LNG). The weld seam formation and the achievable metallurgical and mechanical properties of the hybrid welds were investigated experimentally for two types of filler wire, an austenitic wire dissimilar to the base metal (BM) and an experimentally produced matching ferritic wire. Safe penetration and uniform distribution of the austenitic filler metal in the narrow hybrid weld could only be achieved in the upper, arc-dominated part of the weld. The pronounced heterogeneous distribution of the austenitic filler metal in the middle part and in the root area of the weld could not ensure sufficient notched impact toughness of the weld metal (WM). As a result, a decrease in the impact energy down to 17 ± 3 J was observed, which is below the acceptance level of ≥ 34 J for cryogenic applications. In contrast, the use of a matching ferritic filler wire resulted in satisfactory impact energy of the hybrid welds of up to 134 ± 52 J at the concerned cryogenic temperature of -196 °C. The obtained results contribute to an important and remarkable conversion in automated manufacturing of LNG facilities. In other words, the results will help to develop a new laser-based welding technology, where both quality and productivity are considered. The efficiency of the developed welding process has been demonstrated by manufacturing a prototype where a segment of the inner wall of large size LNG storage tank was constructed. In this concern, hybrid laser arc welding was conducted in both horizontal (2G) and vertical (3G) positions as a simulation to the actual onsite manufacturing. The prototype was fabricated twice where its quality was confirmed based on non-destructive and destructive examinations. © 2023, The Author(s).

关键词： Welds

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Experiment-based conceptualization of an automated disassembly process chain for the recycling of lithium-ion battery modules 10

Experiment-based conceptualization of an automated disassemb...

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10th CIRP Conference on Assembly technology and Systems, CATS 2024

作者： Hölter, Timo Dierksen, Fynn Hendrik Dröder, Klaus TU Braunschweig Institute of Machine Tools and Production Technology Langer Kamp 19b Braunschweig38106 Germany TU Braunschweig Battery LabFactory Braunschweig Langer Kamp 8 Braunschweig38106 Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Riedenkamp 2 Braunschweig38108 Germany

As the volume of end-of-life lithium-ion batteries (LIB) used in electric vehicles increases, so does the demand for recycling to recover valuable active materials as secondary resources, reducing the need for primary raw materials and minimizing supply dependencies. In addition to pyro- and hydrometallurgy recycling processes, an increasingly examined approach is the direct recycling route, which involves disassembling battery systems into modules, modules to cells, and ultimately cells to electrodes. To minimize passive materials such as various metals from the housing, joints, arresters, plastics, foams, and adhesives in the subsequent crushed mass, the introduction of module disassembly processes into the existing LIB recycling process chain is promising for the resulting increase in recyclate purity. This study presents the conceptualization of a LIB module disassembly process chain which aims to elevate the depth of disassembly of LIB during early recycling stages. A reverse engineering approach is used to recover individual cells from two battery modules of one specific automotive manufacturer by removing their casing through milling and disconnecting the cells from the arresters. The experimental results are analyzed for influences on the disassembly possibilities for individual components as well as the interactions within the system, enabling the elaboration of a priority graph and a disassembly plan. In order to allow for scalable recycling process chains suitable for very high quantities, a concept for a fully automated and variant-compatible robot application based on the experiment is derived. Furthermore, the depth of disassembly is compared with the corresponding reduction of passive materials in the crushed mass. The findings indicate that several module components can be disassembled, resulting in cell recovery and a reduction of metal and plastic in the crushed mass by about 17 %, highlighting the importance of robotic disassembly in enhancing mat

关键词： Lithium-ion batteries

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Classification and Evaluation of the Integration of Process Mining and Digital Twins: A Roadmap

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Procedia CIRP 2025年 134卷 467-472页

作者： Maxi Grobis Sven Solterbeck Oliver Kempf Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz“ Germany DB Systel GmbH Jürgen-Ponto-Platz 1 60329 Frankfurt a. Main Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstraße 7a 01069 Dresden Germany

Process mining has established itself as an essential technique for discovering and analyzing business processes by bringing transparency to complex process landscapes. The application of process mining provides a solid foundation for the further development of digital twins - virtual replicas of real systems that are updated in real-time to generate simulations and improve predictions. The combination of process mining with digital twins necessitates an in-depth exploration of the fundamental aspects of this synergy, particularly to delineate the criteria that constitute a digital process twin or an organizational twin. Currently, there are initial research activities and definitions in this area, characterized by significantly divergent approaches. To address this, the authors developed a concept in the form of a roadmap laying the foundations for a future maturity model and utilized the Reference Architecture Model Industry 4.0 (RAMI 4.0) to systematically evaluate the integration and progress of process mining in connection with digital twins and their characteristics.

关键词： Process Mining Digital Twin Maturity Model RAMI 4.0

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In-process evaluation of the grinding process using a new Barkhausen noise method

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Procedia CIRP 2021年 99卷 202-207页

作者： Maximilian Rößler Matthias Putz Carsten Hochmuth Jens Gentzen Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany

While the achievement of size and form tolerances is already state of the art for grinding, there are hardly any industrial solutions to identify thermo-mechanical process loads such as grinding burn. A system was developed, presented, and tested, which allows for the first time the in-process measurement of Barkhausen noise to indicate changes of the boundary zone’s state using a novel kind of sensor. The system enables tactile and non-contact measurement at sampling rates of up to 10 ms. During investigations on hardened shafts of 100Cr6, relevant influences on the in-process Barkhausen noise were identified and evaluated. Furthermore, cause-effect relationships between microstructural effects and the Barkhausen noise were detected.

关键词： Grinding In-process measurement Barkhausen noise

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Transition to a resilient and sustainable energy supply system: Decision support for manufacturing companies 56

Transition to a resilient and sustainable energy supply syst...

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

作者： Dickel, Kilian Juraschek, Max Herrmann, Christoph Institute of Machine Tools and Production Technology Technische Universität Braunschweig Langer Kamp 19b Braunschweig38106 Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Bienroder Weg 54E Braunschweig38108 Germany

Recent developments show that not only material supply chains but also energy supply systems can be hit by strong disruptive forces. This brings new challenges and highlights the importance of a resilient energy supply to the manufacturing industry. These challenges can be solved by implementation of technical solutions and a change of energy supply system designs. However, manifold options available to a company require a methodological approach to rapidly identify the potentially most suitable variants under individual circumstances for a specific factory. This paper introduces a simplified methodology for the first planning steps in the transition towards a resilient energy supply system of production sites. For this purpose, relevant resilience factors are identified and selected for energy supply systems of a factory. With a structured procedure, different technical system combinations are created and evaluated in respect to implementation effort and their potential impact on the resilience factors. Simultaneously, different disruptive scenarios are ranked based on likelihood and expected severity. The impact of these combinations on the energy load profile of the factory is evaluated and the results are presented based on the suitability of each energy supply system alternative in respect to the different disruptive scenarios. This provides information on the potentially most favorable options to the relevant stakeholders for further implementation. To demonstrate the applicability of the developed methodology, a case study on a battery cell factory is presented. The production of batteries is a fast-growing industry with a high relevance for the transition towards a sustainable economy while the battery production itself requires high amounts of electricity and heat at different temperature levels. Alternative supply scenarios besides the unidirectional consumption of fossil fuels are needed in in terms of sustainability and to increase resilience. © 2023 The

关键词： Flexible Energy Supply Renewable Energy Resilience Resilient Factory Systems

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