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SAMPE 2022 Conference and Exhibition

作者： von Helden, Jonathan Schulte, Jonas Janssen, Henning Brecher, Christian Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen52074 Germany Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen University Steinbachstr. 19 Aachen52074 Germany

ISBN: (纸本)9781934551417

Hybrid materials made of fiber-reinforced polymers (FRP) and metals offer great potential for a wide range of applications by synergistic combination of each material’s benefits. Compared to monolithic materials and traditional FRP, fiber-metal laminates (FML) can provide more versatile functionality, better insulation capability and higher weight-specific mechanical properties like impact strength and damage tolerance. However, the production of thermoplastic FML is currently based either on discontinuous manufacturing processes or resource-intensive impregnation presses. In addition, the combination of dissimilar materials results in difficult material separation or recycling. The fraunhofer IPT has developed a continuous and resource-effective consolidation process to manufacture thermoplastic FML that are fully recyclable. During the impregnation and joining process, thin metal belts serve as tools for heat and pressure transfer, which finally form the top layers of the sandwich material. To achieve a strong bond between the core and top layers, a laser-based structuring process for metal surface treatment is used, eliminating the need for poorly recyclable bonding agents. This paper describes the developed process and compares it with traditional production methods. Experimental test results for flax-PLA based FML are presented to show the feasibility of the developed process and the potential for industrial applications. Copyright 2022. Used by the Society of the Advancement of Material and Process Engineering with permission.

关键词： Impact strength

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Comparison of abrasive water jet technologies in terms of performance and kerf geometry accuracy for cutting ceramics

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International Journal of Sustainable Manufacturing 2020年第2-4期4卷 201-215页

作者： Morczinek, Florian Putz, Matthias Dix, Martin Chemnitz University of Technology Reichenhainer Straße 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Hard machining of brittle materials such as ceramics is a process-oriented challenge. For the machining of such materials, abrasive water jet cutting is an appropriate alternative to the commonly used diamond grinding and laser cutting processes. In abrasive water jet machining the injection technology is currently used almost exclusively. Due to the realisation of the suspension jet technology a higher cutting performance can be achieved. In this article, the known injection technology and the suspension technology are compared. To do so, the influences on the quality were examined for trimming technical ceramics. The investigation illustrates that suspension technology trims with a higher accuracy than injection technology in matters of kerf geometry but with a lower material removal rate. © 2020 Inderscience Enterprises Ltd.

关键词： Jets

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The Pathway to Environmentally Friendly Battery Production: Comparison of NMP-Based, Water-Based and Semidry Water-Based Production of NMC622 Cathodes for Lithium-Ion Batteries

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Procedia CIRP 2025年 134卷 819-824页

作者： Matthias Leeb Johannes Lindenblatt Zheng Jia Xiangling Gui Rüdiger Daub Technical University of Munich TUM School of Engineering and Design Institute for Machine Tools and Industrial Management (iwb) Boltzmannstraße 15 Garching 85748 Germany Fraunhofer Institute for Casting Composite and Processing Technology (IGCV) Am Technologiezentrum 10 Augsburg 86159 Germany

The transition to renewable energy sources necessitates the development of environmentally friendly and cost-efficient lithium-ion battery production methods. Traditional cathode production is energy-demanding, primarily due to solvent recovery and drying. This study investigates the water-based semidry production processes for NMC622 cathodes, aiming to reduce the energy-intensive drying phase and eliminate toxic solvents like N-methyl-pyrrolidone (NMP). By substituting NMP with water and employing a semidry approach, the solvent content during production can be significantly reduced. This research compares semidry-coated electrodes with NMP-based and water-based wet-coated electrodes, focusing on the electrode properties and the electrochemical characteristics in full cells. Utilizing an extrusion and calendering method, the semidry process demonstrated a five-fold reduction in solvent use compared to the NMP-based method. However, the semidry-produced electrodes exhibited higher resistance, probably due to the fine distribution of binder and carbon black, which lacked long electron transport pathways compared to the wet-coated electrodes. The water-based wet-coated electrode, with lower initial coulombic efficiency, displayed better performance at higher discharge rates and lower capacity loss over cyclization than the NMP-based reference. This study highlights the potential of water-based semidry production in creating more sustainable and efficient lithium-ion batteries.

关键词： semidry electrode water-based cathode extrusion direct calendering

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Thermographic in-situ investigation of precise electrochemical machining 15

Thermographic in-situ investigation of precise electrochemic...

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15th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2021

作者： Heidemanns, L. Herrig, T. Klink, A. Bergs, T. Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen University Campus-Boulevard 30 Aachen52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 Aachen52074 Germany

Modelling of ECM is a powerful tool to improve the cost- and time intensive tool-development process. While different simulation models for DC-ECM have been published and validated, the virtual prediction of the process variant with oscillating cathode is still hindered by its highly transient nature. In order to develop and later validate a model of PECM, high-resolution information on the temperature profile and gas evolution during one oscillation is required. Temperature and gas concentration both increase during the electric pulses and constantly decrease due to flushing. This paper presents a fixture that allows the thermographic analyses of the PECM process. Consequently, the conditions within the electrolyte channel during PECM are captured which allows a deeper understanding of the process. © 2022 The Author(s).

关键词： Electrolytes

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DIGITAL TWIN VALIDATION FOR THE IN-SITU AUTOMATED FIBER PLACEMENT PROCESS OF THERMOPLASTIC COMPOSITES

DIGITAL TWIN VALIDATION FOR THE IN-SITU AUTOMATED FIBER PLAC...

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SAMPE 2022 Conference and Exhibition

作者： Schulz, Malena Baumann, Heiko Janssen, Henning Brecher, Christian Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen52074 Germany Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen University Steinbachstr. 19 Aachen52074 Germany

ISBN: (纸本)9781934551417

The digital twin is a methodology accelerating process knowledge for the automated fiber placement (AFP) of unidirectional thermoplastic tape with in-situ consolidation. It implies a continuous assessment and evaluation of data allowing a faster process optimization and reducing ramp-up times. In a previous study, a digital twin is developed allowing the interactive visualization of process data within a digital shadow and the interpretation of quality measures based on analytical methods. In this study, the developed digital twin for predicting the degree of bonding is validated by experimental results. By using destructive testing methods, such as interlaminar shear strength tests and microsections, the degree of bonding is quantified. The results are feedbacked to the initial digital twin forecast and a comparison is made. The results disclose the need to calibrate the analytical models as the underlying assumptions do not hold in a realistic environment. Based on these findings, a methodology is presented enabling a fast calibration of the analytical models. Aim is to reduce extensive experimental work for process optimization and, thus, to accelerate the ramp-up for a flexible series production. Copyright 2022 by the fraunhofer institute of Production technology IPT. Used by the Society of the Advancement of Material and Process Engineering with permission.

关键词： Optimization

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Influence of engagement parameters on estimation of tangential cutting force using high-frequency process data of the machine tool

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Procedia CIRP 2023年 118卷 537-542页

作者： Michal Rytir Jonas Rönnecke Albrecht Hänel Petr Kolar Steffen Ihlenfeldt Czech Technical University in Prague Czech Institute of Informatics Robotics and Cybernetics Department of Industrial Production and Automation Jugoslávských partyzánů 1580/3 160 00 Prague Czech Republic Fraunhofer Institute for Machine Tools and Forming Technology IWU Department of Production Digital Twin Nöthnitzer Straße 44 Dresden Germany Technische Universität Dresden Institute of Mechatronic Engineering Chair of Machine Tools Development and Adaptive Controls 01062 Dresden Germany

The machining of high-value products needs advanced quality control to avoid the risk of expensive follow-up operations performed on parts with unacceptable quality. This situation requires the in-process or close to in-process control of the machining operation. The tangential cutting force is a parameter that characterizes the force interaction between the specific workpiece material and the specific tool geometry. This paper presents a method for a tangential cutting force calculation along the given tool path based on processing of the high-frequency data acquired from the machine tool control system with support of the geometric material removal model. The calculated data are compared with the reference dynamometer results. The influence of the variable engagement parameters is demonstrated and discussed from the perspective of the in-process workpiece quality control.

关键词： In-process monitoring leakage model cutting force model spindle current edge computing

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Filling the Semantics Gap in Industrial Communication: Middleware+ for an Internet of Production

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IFAC-PapersOnLine 2021年第1期54卷 432-437页

作者： Raphael Kiesel Arno Weiss Robert H. Schmitt WZL | RWTH Aachen University Aachen Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Fraunhofer Institute for Production Technology IPT Aachen Germany

To enable interoperable communication between enterprise software and industrial assets, the Internet of Production reference model suggests a single platform for routing and data access. This Middleware+ must not only act as a central message broker but also meet the challenge of incompatible data models. However, its exact capabilities remain blurred. We first compile relevant technologies and standards to integrate. Definition of requirements and a software architecture proposal follow. Considering the heterogeneous degree of connectivity within producing companies, we then sketch the path to implementation based on maturity levels. The result is a distributed information system architecture ensuring the rigorous use of semantic information models throughout the entire lifecycle of a product.

关键词： Internet of things flexible reconfigurable manufacturing systems modeling of manufacturing operations enterprise integration systems interoperability protocols information communication

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Demand response for cleaning machines: A comparative study of deep reinforcement learning and model predictive control in application

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Procedia CIRP 2024年 130卷 200-205页

作者： Daniel Fuhrländer-Völker Heiko Ranzau Lena Köhler Matthias Weigold Technical University of Darmstadt Department of Mechanical Engineering Institute for Production Management Technology and Machine Tools (PTW) Otto-Berndt-Str. 2 64287 Darmstadt Germany Fraunhofer Institute for Integrated Systems and Device Technology IISB Schottkystraße 10 91058 Erlangen Germany

Demand response strategies offer significant potential for optimisation of electrical energy consumption in industrial manufacturing. This paper presents a comparative analysis of two demand response algorithms, using model predictive control (MPC) and deep reinforcement learning (DRL). While existing algorithms for demand response implementation often rely on simulation for validation, this study contributes by implementing MPC and DRL on a real aqueous parts cleaning machine, providing a quantitative and qualitative comparison. In the experiments, the MPC algorithm achieves an energy cost reduction of 58%, the DRL of 57%, in comparison to standard operation. The qualitative comparison underscores the importance of domain knowledge in implementing both algorithms effectively. While DRL shows promise in operational efficiency, its black-box nature and implementation challenges warrant careful consideration in industrial settings. This study not only provides insights into the advantages and disadvantages of both methodologies in practical scenarios, but also sets a benchmark for future research in industrial energy optimisation.

关键词： Optimisation sustainability Artificial intelligence shop floor

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Diamond coatings for advanced cutting tools in honing and grinding 6th

Diamond coatings for advanced cutting tools in honing and gr...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Baron, S. Tounsi, T. Gäbler, J. Mahlfeld, G. Stein, C. Höfer, M. Sittinger, V. Hoffmeister, H.-W. Herrmann, C. Dröder, K. Fraunhofer Institute For Surface Engineering And Thin Films Ist Bienroder Weg 54e Braunschweig38108 Germany Institute Of Machine Tools And Production Technology Iwf Langer Kamp 19b Braunschweig38106 Germany

In high-performance machining processes, the cutting tools are an essential factor with regard to the resulting quality of the manufactured components and the efficiency of the entire production chain. For the machining of advanced materials with high hardness and brittleness, tools combining cutting and abrasive machining with high wear-resistance were developed and investigated. Focusing on honing and grinding, the development of application-adapted tools, their coating characteristics, cutting behavior and their improvements of performance are presented. The results demonstrate high wear resistance and high material removal rates in combination with significantly reduced surface roughness. © 2022 The Authors.

关键词： Grinding (machining)

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Comparing the performance of a nested to a continuous evolution strategy with covariance matrix adaption for optimization of drilling EDM 15

Comparing the performance of a nested to a continuous evolut...

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15th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2021

作者： Uhlmann, E. Streckenbach, J. Polte, M. Osmanovic, M. Schick, F. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Germany

Electrical discharge machining (EDM) is a complex manufacturing process where the correlation of the individual process parameters is not fully known. When introducing new materials or complex, individual geometries in EDM, a satisfactory vector of parameters for the process must be found. This challenge is often encountered in the aerospace industry as well as in mold and tool making. One previously successful method to tackle this challenge is the stochastic optimization procedure Evolutionary Strategy (ES). Utilizing an appropriately chosen objective function, the search for a suitable vector of input parameters may be formulated as a mathematical minimization problem over the parameter space. The ES with a covariance matrix adaption (CMA) was utilized to sample from this parameter space in a stochastic manner. Examining the impact of the CMA within an ES is a promising way to gain better insight into the performance of ES. For this purpose, a vector of input parameters was optimized for a drilling EDM process with a comma and a nested comma ES with CMA. It was found that the comma ES led to a reduction in erosion duration tero of 38 % compared to the initially chosen parameters and the nested comma ES led to a reduction in erosion duration tero of 27 % compared to the same initial parameters. The additional information stored in the covariance matrix enables the ES to find a local optimum of the parameter vector faster and more consistently. This fact is verified by use of visualizations of the covariance matrix on a two-dimensional subspace. From these findings it can be concluded, that for the application of the ES to the optimization of EDM processes the CMA should be performed continuously over all generations as opposed to resetting this matrix after a number of generations. © 2022 The Authors. Published by Elsevier B.V.

关键词： Optimization

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