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Manufacturing of high added value titanium components. A South African perspective

IOP Conference Series: Materials Science and Engineering 2018年第1期430卷

作者： D Dimitrov E Uheida G Oosthuizen D Blaine R Laubscher A Sterzing P Blau W Gerber O F R A Damm Department of Industrial Engineering Faculty of Engineering Stellenbosch University South Africa Department of Mechanical and Mechatronic Engineering Faculty of Engineering Stellenbosch University South Africa Department of Mechanical Engineering University of Johannesburg South Africa Fraunhofer Institute for Machine Tools and Forming Technology Germany Aerosud Aviation South Africa

South Africa has significant titanium reserves and is developing strategies to not only provide this raw material on global markets, but to manufacture complex titanium alloy products and participate fully in global supply chains. Pursuing more sustainable process chains, manufacturers are constantly striving to enhance the resource efficiency of their high added value processes. Titanium alloys are used comprehensively in aerospace and biomedical applications, due to its favourable strength-to-weight ratio, corrosion resistance and biocompatibility. These properties, however, contribute to the manufacturing challenges, classifying it as a difficult-to-machine material. Various input factors affect the efficiency of a hybrid process chain. The objectives of this multidisciplinary research group were to demonstrate the reduction of material wastage by up to 50% and machining time up to 20% for selected titanium components. The results clearly demonstrate the ability to increase the technology readiness levels of the selected components and to develop competitive hybrid titanium process chains that will enable South Africa to integrate more into global manufacturing value chains.

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The Interface of an Intrinsic Hybrid Composite – Development, Production and Characterisation

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Procedia CIRP 2017年 66卷 289-293页

作者： R. Kießling J. Ihlemann M. Riemer W.-G. Drossel I. Scharf T. Lampke S. Sharafiev M. Pouya M.F.-X. Wagner Professorship of Solid Mechanics Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Reichenhainer Str. 88 09126 Chemnitz Germany Professorship of Materials and Surface Engineering Chemnitz University of Technology Erfenschlager Str. 73 09125 Chemnitz Germany Professorship of Material Science Chemnitz University of Technology Erfenschlager Str. 73 09125 Chemnitz Germany

Due to a combination of different classes of materials, intrinsic hybrid composites are characterised by high strength and low weight. The mechanical properties of hybrid parts are mainly determined by the interface between the different materials. Consequently, this interface has to be considered in detail within the development of an intrinsic hybrid composite. The general approach of the considered composite is the combination of a mechanical form fit with adhesive bonding. This contribution focuses on the development, production and characterisation of the interface between aluminium and a fibre reinforced polymer as well as of the hybrid composite.

关键词： hybrid composite interface mechanical interlocking cohesive bonding crash performance

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Parallelization in Automated Stem Cell Culture

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Procedia CIRP 2017年 65卷 242-247页

作者： Michael Kulik Jelena Ochs Niels König Christine McBeth Alexis Sauer-Budge Andre Sharon Robert Schmitt Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany Fraunhofer Center for Manufacturing Innovation CMI 15 Saint Mary's Street Brookline MA 02446 USA Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Steinbachstr. 19 52074 Aachen Germany

Stem cells play a dominant role in biological research and have a significant potential, as test systems for drug screening, disease modeling and therapeutic applications. The automated production of different stem cell types such as iPS and MSC has been realized in recent years by a few research groups. Yet, it requires different approaches in parallelization compared to conventional automated production because of the nature of the living cells on the one hand, and the production system with various interconnected devices on the other hand. Within this work, we present an approach for parallel processing on an automated cell culture platform.

关键词： automation parallelization scheduling stem cells

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Tool Technologies for Milling of Hardmetals and Ceramics

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Procedia CIRP 2016年 46卷 299-302页

作者： Thomas Bergs Volkmar Richter Michael Ottersbach Johannes Pötschke Carsten Hochmuth Katia Busch Fraunhofer Institute for Production Technology IPT 52074 Aachen Germany Fraunhofer Institute for Ceramic Technologies and Systems 01277 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

Hardmetals and ceramics are major substrate materials for a wide range of cutting tools and forming dies. Due to their high specific hardness the final part geometry is usually obtained by sintering of preformed green parts, electrical discharge machining, grinding and/or polishing. Machining by milling is not possible due to fast and unpredictable milling tool failures. To enable milling for tungsten carbides and ceramics new tool technologies are developed. The technologies encompass nanoscaled tungsten carbide hardmetals, innovative coating systems, new milling tool designs as well as adapted milling processes. By combining these technologies it becomes possible to mill different grades of hardmetals and ceramics with hardness values over 1200 HV10.

关键词： Milling cutting ultrafine cemented carbides nanoscaled cemented carbides hard machining

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High precision milling with a novel compliant machine tool 16

High precision milling with a novel compliant machine tool

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16th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2016

作者： Uhlmann, E. Oberschmidt, D. Guhde, S. Polte, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780956679086

For precision milling manufacturing machine tools with high stiffness K and high masses m are state of the art. Usually this will be achieved due to heavy and large machine beds and frames. Hence, a new approach based on the compensation of the dynamic dislocation was investigated. The aim of this new approach was to develop a high dynamic machine tool with a compliant machine frame. Therefore, a novel compliant three- Axes machine tool for high precision milling based on an Ethercat technology® and the open source ethercat master etherlab machine is developed by the Technische Universität Berlin and the fraunhofer institute for Production Systems and Design technology. For the dynamic dislocation a Kalman-filter is integrated in the machine control which calculates the tool body with respect to the tool-center-point TCP and its velocity v. For the verification milling structures are manufactured with the compliant machine tool. Various setups were investigated, braced, compliant without compensation and compliant with compensation. Further the feed speed vf and the gain factor of the control system Kv were modified. To measure the average diameter Dav and the concentricity Cδ of the milling structures, the coordinate measurement machine O-INSPECT of the company CARL ZEISS IMT was used. As a result the compliant machine tool can be used for high precision milling processes. Finally, the compliant machine tool is compared with the WISSNER GAMMA 303 HIGH PERFORMANCE, WISSNER GMBH, GÖPPINGEN, Germany.

关键词： Milling (machining)

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CBN-micro-milling tools for machining hardened steel moulds 16

CBN-micro-milling tools for machining hardened steel moulds

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16th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2016

作者： Uhlmann, E. Oberschmidt, D. Polte, M. Polte, J. Börnstein, J. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780956679086

High-precision cutting of hardened steel with geometrical defined cutting edge is restricted due to excessive and random tool wear. For serial production of precision plastic parts hot embossing tools and micro injection moulding tools with high requirements regarding geometrical accuracy and surface roughness are needed. Cutting materials based on cubic Boron Nitride (cBN) are successfully used in macro-machining of hardened steel. In this paper, detailed information about machining hardened steel with micro-milling tools with cutting edges made of cBN are given. An arithmetical mean deviation Ra = 19 nm could be achieved using a high-precision micro-milling machine tool with ball bearing guideways and spindle.

关键词： Milling (machining)

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Geometric deviations of ground micro-milling tools and their influences on the cutting performance 16

Geometric deviations of ground micro-milling tools and their...

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16th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2016

作者： Uhlmann, E. Oberschmidt, D. Kuche, Y. Polte, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

for micro-milling tools with decreasing diameter D

ISBN: (纸本)9780956679086

for micro-milling tools with decreasing diameter D

关键词： Surface roughness

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Manufacturing, replication and assessment of microfluidics for blood plasma separation 16

Manufacturing, replication and assessment of microfluidics f...

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16th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2016

作者： Uhlmann, E. Hein, C. Polte, M. Polte, J. Spielvogel, A. Herms, K. Oberschmidt, D. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780956679086

Point of care diagnostics gain importance with regard to novel diagnostic techniques. Future applications, for example based on cell-free DNA, are prenatal or cancer diagnostics. With regard to these methods a large influence of natural blood degradation during full blood storage and transport before laboratory based separation restricts possible applications. With a point of care plasma separation device, the plasma can be separated from full blood directly after blood collection. Thus, diagnostic markers remain undamaged and allow a highly specific detection. Targeting microfluidics for point-of-care blood plasma separation, this work presents the development of a microfluidic blood plasma separation device along a novel process chain. Besides system design and manufacturing technologies for prototypes, the development of technologies for replication, closure of microfluidics and affecting of surface properties are under the special scope of this investigation.

关键词： Microfluidics

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Influence of the rake angle on the surface formation during micro shaping of submicron optical structures in Au-layers 16

Influence of the rake angle on the surface formation during ...

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16th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2016

作者： Uhlmann, E. Kühne, S. Jagodzinski, M. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany

ISBN: (纸本)9780956679086

The manufacturing of discontinuous micro-optical structures in the submicron range by shaping processes places high demands on the accuracy and reproducibility. With diffractive optical elements (DOE), the requirements can be in the nanometre range. Lithographic and mechanical procedures compete to achieve these requirements with a high variety of shapes. The mechanical production by ultra-precision machining (UPM) allows higher degrees of freedom and the manufacturing of optics with a higher efficiency. By comparison, lithographic processes ensure a reproducible accuracy. To eliminate this disadvantage, a further development of machine technology and process technology is necessary. For the mechanical production of planar diffractive optical structures, galvanic gold is an established material. In order to achieve the same results in structuring free-form surfaces on 5- Axis machines, the machine kinematics and the tool guide have to be reconsidered. The lower the number of axes involved, the higher is the achievable accuracy. However, this reduction leads to variable rake angles and thus to variable chipping conditions in the sagittal plane. In particular, high process forces due to negative rake angles are suspected to cause profile deformations. Therefore, the influence of the varying conditions on the surfaces in the production of discontinuous micro-optical structures (blazed gratings) was investigated. Process forces, roughness, profile shape and tool wear were considered to understand the interactions and the development process. The studied structures have a height of less than 100 nm. Since the manufacturing of diffractive optics requires very large processing times, the wear is of major importance. Due to the manufacturing process the wear takes on a specific form. It has been shown that the tool guidance has a huge impact on the results.

关键词： Manufacture

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Process development and tooling design for intrinsic hybrid composites

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Journal of Physics: Conference Series 2017年第1期896卷

作者： M Riemer R Müller W G Drossel D Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz www.iwu.fraunhofer.de

Hybrid parts, which combine the advantages of different material classes, are moving into the focus of lightweight applications. This development is amplified by their high potential for usage in the field of crash relevant structures. By the current state of the art, hybrid parts are mainly made in separate, subsequent forming and joining processes. By using the concept of an intrinsic hybrid, the shaping of the part and the joining of the different materials are performed in a single process step for shortening the overall processing time and thereby the manufacturing costs. The investigated hybrid part is made from continuous fibre reinforced plastic (FRP), in which a metallic reinforcement structure is integrated. The connection between these layered components is realized by a combination of adhesive bonding and a geometrical form fit. The form fit elements are intrinsically generated during the forming process. This contribution regards the development of the forming process and the design of the forming tool for the single step production of a hybrid part. To this end a forming tool, which combines the thermo-forming and the metal forming process, is developed. The main challenge by designing the tool is the temperature management of the tool elements for the variothermal forming process. The process parameters are determined in basic tests and finite element (FE) simulation studies. On the basis of these investigations a control concept for the steering of the motion axes and the tool temperature is developed. forming tests are carried out with the developed tool and the manufactured parts are analysed by computer assisted tomography (CT) scans.

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