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Process combinations for the manufacturing of metal-plastic hybrid parts

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

作者： W-G Drossel C Lies A Albert R Haase R Müller P Scholz Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

The usage of innovative lightweight materials and processing technologies gains importance in manifold industrial scopes. Especially for moving parts and mobility products the weight is decisively. The aerospace and automotive industries use light and high-strength materials to reduce weight and energy consumption and thereby improve the performance of their products. Composites with reinforced plastics are of particular importance. They offer a low density in combination with high specific stiffness and strength. A pure material substitution through reinforced plastics is still not economical. The approach of using hybrid metal-plastic structures with the principle of 'using the right material at the right place' is a promising solution for the economical realization of lightweight structures with a high achievement potential. The article shows four innovative manufacturing possibilities for the realization of metal-plastic-hybrid parts.

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Technological and Simulative Analysis of Power Skiving

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Procedia CIRP 2016年 50卷 773-778页

作者： Fritz Klocke Christian Brecher Christoph Löpenhaus Philipp Ganser Julian Staudt Markus Krömer Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 52074 Aachen Germany Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen Steinbachstraße 19 52074 Aachen Germany

Power skiving is a modern and productive machining process in the manufacturing of cylindrical internal gears and external gears surrounded by interfering contours. The influence of geometric process settings on characteristic values such as the chip thickness or cutting and sliding velocities will be investigated. Therefore, a numerical simulation based on a penetration calculation of the process is performed. With a demonstration part, cutting trials are conducted and the resulting tool wear is analyzed. Because chip welding can be a problem in power skiving, the investigation covers the influence of process parameters and chip geometry on chip welding, as well. The results support design and process engineers in the optimization of the power skiving process regarding productivity as well as quality.

关键词： Simulation driven design Manufacturing Process design Power skiving Gears Surface defects

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Model-based Decision Support in Supply Chains – Requirements for Monetary Supply Risk Quantification

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Procedia CIRP 2016年 57卷 171-176页

作者： Johann Philipp von Cube Lasse Härtel Robert Schmitt Fraunhofer Institute for Production Technology Steinbachstraße 17 Aachen 52074 Germany Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Steinbachstraße 19 Aachen 52074 Germany

Optimization of the total risk level by economically feasible risk mitigation can only be achieved through a well-grounded monetary evaluation of the current risk situation. In the field of material supply and procurement directly affecting production and distribution processes a lack of such quantitative simulation model has been identified. Efficient modeling and simulation of monetary supply risk quantification in manufacturing enterprises requires target oriented simplification of the quantification model. Thereby requirements from three different disciplines need to be considered: (1) procurement in supply chains, (2) supply risks, and (3) monetary risk quantification. In this paper we propose a target oriented approach to deviate and discuss requirements for an applicable monetary supply risk quantification model particularly focusing on supply risks providing meaningful results to derive reasonable risk mitigation measures. Hence, a requirement checklist will be provided to be considered in development of monetary supply risk quantification models.

关键词： risk quantification monetary assessment supply chain risk management modeling requirements

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Cybernetic Approach for Controlling technology Management Activities

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Procedia CIRP 2016年 41卷 437-442页

作者： Günther Schuh Linda Kramer Laboratory for Machine Tools and Production Engineering RWTH Universtiy Aachen Steinbachstr. 19 52074 Aachen Germany Fraunhofer Institute for Production Technology IPT Department of Technology Management Steinbachstr. 17 52074 Aachen Germany

The growing complexity, relevance and speed of technological developments present significant challenges for technology-oriented organizations and the necessity to focus intensified on their technology management activities to react and deal more effectively with performance issues. Therefore, a well-structured and comprehensible technology management process is crucial for a company's success in terms of e.g. ensuring a sustainable and efficient allocation of resources with the purpose to persist in the competitive arena. On this account it is essential and important for an organization to be aware of the performance and the cause-effect-relations of technology management activities and to keeping up with technological progress and its influences in order to evaluate and design a company's technology management efficiently. A further challenge results in the often multifunctional and cross-sectional organization of technology management which demands an integrated consideration within the cybernetic framework for controlling technology management activities. In spite of the recognition of its strategic relevance only fragmented and insufficient concepts as well no accurately definition regarding controlling of technology management activities exists. However it is essential to know the performance of the technology management for designing a result-oriented (effective & efficient) technology management for an organization to be able for acting successful and sustainable. Companies lack of an adequate tool and/or approach to bridge the gap between determine the right strategic aims and their realization as well as simultaneous control of technology management activities. This deficit prevents the development of a cybernetic framework including e.g. measuring instruments or maybe a set of different controlling tools to assess, monitor and to affect activities within the technology management. This paper illustrates an academic research development in progress and pur

关键词： controlling of technology management activities performance measurement technology management effectiveness cybernetic

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Integrated Evaluation System for the Strategic Management of Innovation Initiatives in Manufacturing Industries

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Procedia CIRP 2016年 40卷 335-340页

作者： H. Kohl R. Orth O. Riebartsch F. Hecklau Department Sustainable Corporate Development Institute for Machine Tools and Factory Management Technical University Berlin 10587 Berlin Germany Department for Corporate Management Fraunhofer Institute for Production Systems and Design Technology (IPK) 10587 Berlin Germany

The innovation capability of industrial organizations is an essential prerequisite to stay ahead of the global competition by adapting flexible to the rapidly changing customer requirements. However, the success of innovation initiatives is often at risk, due to short-sighted, unsystematic planning-, implementation- and evaluation activities. For this purpose an integrated evaluation approach has been developed by fraunhofer IPK to manage the lifecycle of an innovation initiative in terms of implementation progress and operational performance in a sustainable way. The Evaluation System follows a multi-perspective approach that involves internal and external stakeholders by applying a combination of evaluation instruments including key performance indicators, self-assessment- and audit procedures as well as monitoring- and reporting tools. As a main output of the Evaluation System, specific improvement suggestions and action plans can be derived to react agile on potential challenges.

关键词： Evaluation Integrated Management System Innovation Sustainability Manufacturing Industries

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Thermal Investigation of Interaction between High-power CW-laser Radiation and a Water-jet

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Physics Procedia 2016年 83卷 317-327页

作者： Christian Brecher Henning Janssen Markus Eckert Florian Schmidt Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 Aachen 52074 Germany Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Steinbachstraße 19 Aachen 52074 Germany

The technology of a water guided laser beam has been industrially established for micro machining. Pulsed laser radiation is guided via a water jet (diameter: 25-250 μm) using total internal reflection. Due to the cylindrical jet shape the depth of field increases to above 50 mm, enabling parallel kerfs compared to conventional laser systems. However higher material thicknesses and macro geometries cannot be machined economically viable due to low average laser powers. fraunhofer IPT has successfully combined a high-power continuous-wave (CW) fiber laser (6 kW) and water jet technology. The main challenge of guiding high-power laser radiation in water is the energy transferred to the jet by absorption, decreasing its stability. A model of laser water interaction in the water jet has been developed and validated experimentally. Based on the results an upscaling of system technology to 30 kW is discussed, enabling a high potential in cutting challenging materials at high qualities and high speeds.

关键词： Laser-Water-Jet High-Power High DOF Beam Guiding

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Automated Dressing of Graphite Electrodes for Electrical Discharge Machining (EDM) of Seal Slots in Turbine Components

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Procedia Manufacturing 2016年 6卷 45-52页

作者： Eckart Uhlmann David C. Domingos Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 10587 Berlin Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstrasse 8-9 10587 Berlin Germany

The die-sinking EDM is applied in the aerospace industry for the machining of seal slots in blades and in structural components made of nickel-base alloys, normally applying graphite electrodes. The objective of this work was the development of a technology to dress the graphite electrodes inside the EDM machine tool, with the aim of rebuilding the original shape of the worn electrodes between EDM cycles. The milestones consisted on (I) understanding the wear behavior of the electrodes while machining the slots, (II) the development of the dressing technology applying the DoE-method and determination of statistically high influencing parameters, and finally (III) the integration of the dressing technology into the process chain.

关键词： die-sinking EDM dressing of electrodes nickel-base alloy turbine components process automation.

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Situation Adapted Field Service Support Using Business Process Models and ICT Based Human-machine-Interaction

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Procedia CIRP 2016年 47卷 240-245页

作者： Eckart Uhlmann Claudio Geisert Niels Raue Christian Gabriel Fraunhofer Institute for Productions Systems and Design Technology IPK Pascalstraße 8 – 9 10587 Berlin Germany Institute for Machine Tools and Factory Management Technical University Berlin Pascalstraße 8 – 9 10587 Berlin Germany

The use of conventional service manuals is still common among service technicians during on-site support. If problems occur during the service process, service technicians have to analyze the situation and react accordingly. Problem analysis is subject to uncertainty in time, because the optimal course of action strongly depends on the current situation. Therefore, intelligent situation adapted support is needed to replace static guidance. This article describes a concept for the generation of interactive and situation adapted service instructions that are dynamically derived from a service process model. After a brief introduction to on-site service support, the article describes in detail how service processes can be modelled by using the method of Integrated Enterprise Modeling (IEM). Subsequently, it shows how and in which phases automated test routines can be used to support the service process, followed by a critical discussion of possible information and communication technology (ICT) architectures to implement human-machine-interaction. The concept includes an ICT-based approach for human-machine-interaction to trigger test routines on the machine to receive information about the condition of the machine. For Industrial Product-Service Systems (IPS 2 ), the presented approach offers several benefits compared to existing approaches. These include the ability of tracking and influencing service processes as well as the simple adaption of new IPS 2 modules in case of changing business models or customer requirements. The article concludes giving a specific scenario and an outlook on future research to be done.

关键词： Service Diagnosis Human-machine-Interaction ICT Industrial Product-Service Systems

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Micro structuring of coated tools for dry Sheet metal forming of aluminium alloys 15

Micro structuring of coated tools for dry Sheet metal formin...

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15th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2015

作者： Börner, Richard Scholz, Peter Kühn, Ralf Schubert, Andreas Zeidler, Henning Müller, Roland Technische Universität Chemnitz Prof. Micromanufacturing Technology Chemnitz09107 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz09126 Germany

ISBN: (纸本)9780956679079

Sheet metal forming is characterised by strong frictional forces involving an increase of the temperature and a tendency to adhesion. Consequently, use of lubricants is essential yet, especially for forming of Aluminium alloys. Furthermore, lubricant reduces tool wear. However, for economical and ecological reasons, dry forming is highly desired. Avoiding the application of lubrication requires a reduction of the coefficient of friction and the tendency for adhesion in dry forming processes. One approach is to increase the nominal surface pressure by micro structuring the tool. Additionally, different carbon based layers (a-C:H:Si and CVD diamond) are applied on the tool to reduce wear and tendency to adhesion. For using a a-C:H:Si layer, uncoated steel drawing tools are micro structured with calottes by milling. Because of a higher thickness of CVD diamond layers, calottes have to be generated directly in the coating using ablating processes like electrical discharge machining. To emulate the tribological system of a sheet metal forming process and characterise it, strip drawing tests are done. For a-C:H:Si coated drawing tools, the test results show a significant reduction of the coefficient of friction in micro structured, compared to polished drawing tools. To further increase the wear resistance of the tool it is intended to apply CVD diamond layers on steel tools as soon as the process is operational.

关键词： Metals

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Surface Finish Machining of Medical Parts Using Plasma Electrolytic Polishing

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Procedia CIRP 2016年 49卷 83-87页

作者： Henning Zeidler Falko Boettger-Hiller Jan Edelmann Andreas Schubert Technische Universität Chemnitz Professorship Micromanufacturing Technology Reichenhainer Str. 70 09126 Chemnitz Germany Beckmann-Institut für Technologieentwicklung e.V. Turleyring 15 09376 Oelsnitz/E. Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Biomanufactured parts, for implant or generally in-vivo use, have high requirements for surface properties. Depending on their field of application, not only smooth, but also well-defined surfaces, i.e. roughness parameters, must be set to allow for the respective functionalities such as optimal cell growth or minimal friction and wear. While for many parts mechanical polishing procedures are state-of-the-art, which are time-consuming and limited in their flexibility, established electrolytic polishing processes often incorporate aggressive media such as acids. Plasma electrolytic Polishing (PeP), a high-voltage process combining anode dissolution and plasma-chemical processes, can be considered a suitable alternative. The paper focusses on current investigations of PeP and shows application scenarios, also pointing out necessary development directions to introduce PeP to industrial biomanufacturing process chains.

关键词： Plasma electrolytic Polishing PeP surface functionalisation polishing

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