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Innovative actuating process for machining CFRP with force-controlled radial feed movement

Procedia CIRP 2023年 119卷 669-674页

作者： Marie Peter Konstantin Sauer Joachim Regel Martin Dix Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

The use of lightweight materials such as carbon fibre reinforced plastics (CFRP) is increasing due to the demand for rising resource and energy efficiency, especially in the aerospace and automotive industries. Because of the high delamination tendency of these materials and their abrasive impact on the tool, the challenges in machining CFRP lie primarily in the drilling process and thus in the design of the drilling tool. In this paper, an innovative design of a drilling tool for machining CFRP with force-controlled radial feed movement of the cutting edges is presented. The aim of this tool is to create a tool axial force free process that uses a force-controlled radial feed motion, which matches the chip cross-section to the wear condition of the cutting edge. The tool concept is explained based on the functionality of the actuating process. Tests were evaluated with regard to process forces and drilling quality to show that the tool is capable of producing delamination-free bores in a tool axial force free process.

关键词： tool design adaptive control actuator drilling composite

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Increasing the Relative Density of Additively Manufactured Tungsten Carbide-Cobalt Tool Electrodes for EDM 38

Increasing the Relative Density of Additively Manufactured T...

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38th Annual Meeting of the American Society for Precision Engineering, ASPE 2023

作者： Uhlmann, Eckart Polte, Mitchel Hörl, Robert Reimann, Robert Braun, Thomas Hocke, Toni Technische Universität Berlin Institute for Machine Tools and Factory Management Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

ISBN: (纸本)9781887706599

The investigation of novel materials for the use of tool electrodes for electrical discharge machining (EDM) is necessary to meet the increasing demands for complex products to be machined. Continuous product developments require improvements in manufacturing processes such as Sinking Electrical Discharge Machining (S-EDM). To meet these requirements, the development of customized EDM-processes and innovative tool designs is essential. Additive Manufacturing (AM) enables the production of sophisticated tool electrode geometries. This includes internal flushing channels for EDM-processes with minimal design constraints. Laser Powder Bed Fusion (LPBF) is a suitable method for this purpose. The presented paper shows an investigation to further increase the relative density ρrel of additively manufactured S-EDM tool electrodes using tungsten carbide-cobalt (WC-Co) as material for tool electrodes. © 2023 Proceedings - ASPE 2023 Annual Meeting. All rights reserved.

关键词： Electrodes

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The Impact of Post-Processing Heat Treatment on the Magnetic Properties of Additively Manufactured Nd-Fe-B Magnets

SSRN

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SSRN 2024年

作者： Bittner, Florian Kumar Putta, Akhil Juerries, Florian Woodcock, Thomas George Drossel, Welf-Guntram Thielsch, Juliane Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Leibniz IFW Dresden Institute for Metallic Materials Dresden Germany Chemnitz University of Technology Institute for Machine Tools and Production Processes IWP Chemnitz Germany

The effect of post-process heat treatment on microstructure and magnetic properties by laser powder bed fusion (LPBF) additively manufactured Nd-Fe-B magnets was studied in dependence of heat treatment temperature and as built condition. The microstructure of the magnets in the as built condition is partly amorphous. The volume fraction of the amorphous phase depends on the LPBF manufacturing parameters of the magnets, and a subsequent heat treatment above 550°C leads to its crystallization with a corresponding, remarkable improvement in the magnetic properties. Higher heat treatment temperatures allow the precipitation of a-Fe in the microstructure, which deteriorates coercivity but increases remanence. Magnets with high initial volume fraction of amorphous constituents require higher heat treatment temperatures to obtain optimal magnetic performance and show an increased stability against overaging. © 2024, The Authors. All rights reserved.

关键词： Magnetic properties

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forming Limit of Dual Phase Steel: An Experimental and Numerical Investigation 14th

Forming Limit of Dual Phase Steel: An Experimental and Numer...

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14th International Conference on technology of Plasticity, ICTP 2023

作者： Müller, Martina Fehlemann, Niklas Herrig, Tim Lenz, David Könemann, Markus Bergs, Thomas Münstermann, Sebastian Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 Aachen52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstrasse 17 Aachen52074 Germany Institute of Metal Forming IBF RWTH Aachen University Intzestrasse 10 Aachen52074 Germany

ISBN: (纸本)9783031409196

forming limit diagrams and forming limit curves are used to determine the failure limits of sheet metal materials by conducting a forming limit analysis. The aim is to enable the selection of suitable materials, geometries and process parameters at an early stage in the component development. In this way, engineering time and costs can be reduced. In addition to experimental forming limit analyses, different models and model approaches exist to numerically predict damage and failure. All have in common that calibration is necessary based on experimental investigations. The correspondingly determined parameters specify when ductile damage initiation begins, how it evolves, and how the material finally fails. Thus, the calibration and the parameters determined have a significant impact on the models’ accuracy. The present work focuses on the numerical prediction of DP 800 dual phase steel in a Nakajima test using a modified Bai-Wierzbicki model. Besides the calibration influence of the damage model coming from a non-unique parameter selection is investigated. A sensitivity analysis of the experimentally determined parameters of the damage model is carried out with the aim of predicting the crack initiation with high accuracy and to determine the influence of the calibrated parameters, especially the range between the damage initiation locus, the failure locus and the damage evolution rate. The objective is to determine which damage model parameters possess a high influence on the failure prediction, in order to be able to make a risk assessment with regard to the prediction accuracy for later applications. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Calibration

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A case study on the use of open source hardware in mechanical engineering 34

A case study on the use of open source hardware in mechanica...

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34th CIRP Design Conference, CIRP 2024

作者： Veliu, Cäcilia Petzold, Valentin Reichelt, Dirk Stange, Maximilian Ihlenfeldt, Steffen Dresden University of Applied Sciences Friedrich-List-Platz 1 Dresden01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 Chemnitz09126 Germany Institute of Mechatronic Engineering Technical University Dresden Helmholtzstr. 7a Dresden01069 Germany

Open Source Hardware (OSH) enables innovative developments and business models. The OSH approach creates new forms of cross-company product development and community-based innovation processes. Open source has been state of the art in software industry for years. When it comes to OSH projects, however, the focus is primarily on the consumer sector. The use of OSH for industrial products, especially in mechanical engineering, is still in its early stages. The paper presents a case study on the development of an application module based on OSH components in a R&D testbed. The developed module is intended to enable electronic functional testing. For this purpose, the development process involved, among other things, creating solutions for a tool changing system. Using the case study, we analyse the advantages and disadvantages of the open source licenses used and derive implications for the R&D process. Building on this, various concepts for the use, adaptation and expansion of OSH components and the resulting implications for development processes and business models are presented. The case study is used to analyse which established open source software concepts can be transferred to material assets, but also which additional requirements arise from OSH components, e.g. in the area of safety. © 2024 The Authors. Published by Elsevier B.V.

关键词： Software testing

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Increasing Energy Efficiency in Hot forming Processes Through Multivalent Data Use 9

Increasing Energy Efficiency in Hot Forming Processes Throug...

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9th International Conference on Hot Sheet Metal forming of High-Performance Steel, CHS2 2024

作者： Polster, Stefan Boesler, Martin Straube, Oliver Lösch, Siegfried Brenne, Thomas Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany Gestamp Autotech Engineering Deutschland GmbH August-Thyssen-Str. 1 Ludwigsfelde14974 Germany AutoForm Engineering Deutschland GmbH Joseph-von-Fraunhofer-Straße 13a Dortmund44227 Germany

ISBN: (纸本)9780930767303

The energy policy requirements help to make industrial production more sustainable and environmentally friendly, reduce energy consumption and lower the overall costs for businesses. There is a great need for action to increase energy efficiency in production in press hardening processes through efficient technologies along entire process chains. In such production processes and process chains, data accumulates from a wide variety of sources, including machine controls, sensors, material data and simulation data from process design. The logical next step is to utilize this data along with machine learning and optimization methods to control the process and pursuing objectives like optimal quality, minimal energy, or fast cycle times. This is where the proposed method of this work comes in. The main contribution of this work is a methodology to schematically describe and handle process optimizations model-based. In addition, this method is demonstrated on a hot forming process using hybrid (simulation and experimental) data. It is shown that the process can be optimized regarding its energy consumption while complying with additional technical and quality boundary conditions. © CHS2 2024 . All rights reserved.

关键词： Energy efficiency

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Design and Damping Characterization of Sandwich Composite Made of Particle-Filled Hollow Spheres and Steel Sheets

SSRN

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SSRN 2024年

作者： Zhou, Xin Penter, Lars Jehring, Ulrike Göhler, Hartmut Weißgärber, Thomas Ihlenfeldt, Steffen Chair of Machine Tools Development and Adaptive Control Institute of Mechatronic Engineering Technische Universität Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Germany Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM Branch Lab Dresden Germany

Sandwich composites of particle-filled hollow sphere structures (PHSS) and steel plates offer outstanding lightweight and damping properties, making them ideal for high-speed machine tool components under dynamic loads. Previous research has focused on single particle-filled hollow sphere (PHS) and small-sized PHSS, leaving gap in understanding of the behavior of PHSS/steel sandwich composites. As a result, this material cannot yet be used in the design of machine tools. In this study, a test rig was developed, a design of experiments approach and response surface analysis were used to investigate the effect of design parameters (shell and core thickness), and particle parameters (filling ratio and particle size) on the damping performance of PHSS/steel sandwich. The experimental results indicate that the design parameters have a more significant influence on damping, so they should be given priority in the design of PHSS/steel sandwiches. Secondly, the correlation between design and particle parameters substantially affects the damping performance of the sandwich. Minimizing particle size, increasing filling ratio, thinning the face layer, and thickening the core layer significantly increase structural *** address the manufacturing tolerances of the cellular structure, this study develops a finite element (FE) model-based optimization approach that accurately determines the material parameters of PHSS. These parameters were used in a FE-model of PHSS/steel composite using identified contact parameters by minimizing the difference of measurement and simulation. It shows that the homogenized material model and linear model using global damping parameters accurately replicates the dynamic properties of PHSS/steel sandwich composite in low vibration modes. © 2024, The Authors. All rights reserved.

关键词： Damping

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Shaping of Sharp-Edged Design Elements by Electromagnetic forming 13th

Shaping of Sharp-Edged Design Elements by Electromagnetic Fo...

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

作者： Psyk, Verena Scheffler, Christian Stalmann, Albrecht Goede, Martin Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Volkswagen AG Wolfsburg Germany

ISBN: (纸本)9783030753801

Modern car body design includes parts with sharp-edged elements, which are challenging for conventional sheet metal forming technologies. This is especially critical when implementing aluminum parts in order to consider lightweight design requirements. Applying high strain rates allows increasing formability for numerous materials, including typical aluminum alloys used in the automotive industry. Therefore, integrating high-speed forming into a conventional process can help to extend forming limits. The feasibility of locally sharpening a deep-drawn radius by integrated electromagnetic forming was proved in the literature, but up to now, the investigated target radii were much larger compared to the sheet thickness. The presented paper shows that target radii in and below the size of the sheet thickness are possible by this process combination. Based on a simplified 2D component geometry, complementary experimental and numerical investigations served for developing different variants of a modular test tool and analyzing the influence of important process and tool parameters on the forming result. © 2021, The Minerals, Metals & Materials Society.

关键词： Automotive industry

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Planar 3D-Printing and Intrinsic Heat Generation Thermoforming of a Fully Customizable Ankle Orthosis – A Feasibility Approach

Planar 3D-Printing and Intrinsic Heat Generation Thermoformi...

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Integrated Systems in Medical Technologies (ISMT)

作者： Johannes Knecht Marcel Müller Franziska Valerie Hagenauer Linda Weisheit Valentin Wilhelm Mauersberger Lukas Boxberger Biomechatronics Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Technical Design Technical University of Dresden Dresden Germany

ISBN: (数字)9798350375527

ISBN: (纸本)9798350375534

There is a wide spectrum of injuries and medical conditions that are treated with the use of orthoses. For better comfort fully customized orthoses are designed and manufactured via 3D-printing or thermoforming thermoplastic casts with a low glass transition and softening temperature nowadays. This study aims to print a planar orthosis design and then thermoform the orthotic blank with intrinsic heating to get the final customized design depending on patient's needs. After identifying possible thermoplastic polymers for the application with differential scanning calorimetry (DSC) to determine thermal properties, tensile testing for mechanical properties and peel-off testing to measure multi material printing adhesion, the final orthosis blank is printed using Wire-EncapsulatingAdditiveManufacturing to integrate heating wires into the structure and create the intrinsic ability of heat generation for the thermoforming process.

关键词： Heating systems Printing Temperature Wires Thermoforming Mechanical factors Softening Plastics Wearable devices Testing

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Concept for a Function-oriented Ecology Analysis in machinery and Plant Engineering 30

Concept for a Function-oriented Ecology Analysis in Machiner...

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30th CIRP Life Cycle Engineering Conference, LCE 2023

作者： Riesener, M. Kuhn, M. Ruschitzka, C. Schuh, G. Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Aachen Germany Fraunhofer Institute for Production Technology IPT Aachen Germany

Sustainability is becoming increasingly important, especially for the manufacturing industry due to its high resource consumption and CO2 emissions. Transparency about the environmental impact of products along their entire life cycle is a necessity for creating a shift towards sustainability. However, the possibilities for influencing sustainability are not directly apparent using existing methods such as the life cycle assessment. Within those methods, the use phase is only insufficiently analysed and a differentiated consideration of lifetimes and recovery processes of individual product scopes is not possible. Thus, there is no overview of the possible levers for improving the environmental sustainability performance, especially when dealing with complex products in industries such as machinery and plant engineering. Therefore, this paper introduces a sustainability assessment for machines and plants by focusing on life cycles of individual product scopes in order to enable a realistic analysis of the environmental impact along the entire product life cycle. Based on an assignment of the measured ecological criteria to the product structure and functional structure, fields of action for the development of ecologically improved products can be identified. © 2023 The Authors. Published by Elsevier B.V.

关键词： Life cycle

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