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14th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2020

作者： Rößler, Maximilian Putz, Matthias Hochmuth, Carsten Gentzen, Jens Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 Chemnitz09126 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. © 2021 The Authors. Published by Elsevier B.V.

关键词： Grinding (machining)

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Investigation of Surface Characteristics in Magnetic Field assisted Electrical Discharge Machining

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Procedia CIRP 2024年 123卷 416-421页

作者： Viet D. Bui André Martin Thomas Berger Andreas Schubert Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany

Electrical discharge machining (EDM) has demonstrated its promising potential for surface modification. The integration of materials from tool electrode or powder that is mixed into the dielectric fluid has proven to modify the workpiece surface to enhance its mechanical properties, realize antibacterial effects, or increase biocompatibility. Recent EDM studies showed that due to non-contact forces, properties of the modified surface such as roughness values and the thickness of modified layer were significantly influenced when using magnetic field assisted EDM. Consequently, in this study, an external magnetic field with a strength of 0.66 T is used to assist the material transfer from tool electrode to workpiece surfaces during the EDM process. Pure silver and copper tools with a diameter of 2 mm are used to modify surfaces of Ti6Al4V workpieces at a discharge energy of 125 µJ with different polarities. Results show that the assistance by magnetic field significantly increases the content of transferred material from tool electrode to the workpiece surface. Additionally, it increases material removal rate and reduces the modified layer thickness. Magnetic field assisted EDM is a potential technology for improving the efficacy of the EDM surface modification.

关键词： EDM magnetic field deposition modified surface

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Digital Twins in 3d Concrete Printing: Information Model, Enablers, and Major Challenges

SSRN

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SSRN 2024年

作者： Sokolov, Dmitrii Dementyev, Alexander Hänel, Albrecht Ihlenfeldt, Steffen Mechtcherine, Viktor Institute of Construction Materials TU Dresden Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology Dresden Germany TU Dresden Dresden Germany

The Digital Twin (DT) is one of the most promising approaches to digitalisation of industrial processes in Industry 4.0. The interconnection of two entities – a real world and its virtual replica via two-way data communication is the key feature of the Digital Twins, which should enable the handling of high complexity systems. In the field of 3D Concrete Printing (3DCP), DTs have great potential not only to improve design, construction, and maintenance of concrete structures, but foremost to facilitate technological development in regard to robustness, reliability, scalability and market readiness. Combining a pool of well-established and yet growing technologies, DTs in 3DCP deal with highly demanding materials whilst facing their own, unique challenges. This paper explores the burgeoning landscape of DT enablers, highlights their specificities in regard to integration into a DT in 3DCP, addresses particular challenges, reveals technical boundaries, and proposes possible ways to overcome some of them. © 2024, The Authors. All rights reserved.

关键词： Cyber Physical System

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Antibacterial Surface Protection using Electrical Discharge Machining with Zinc Tool Electrode for Medical Devices

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Procedia CIRP 2024年 125卷 278-283页

作者： Viet D. Bui André Martin Thomas Berger Philipp Steinert Andreas Schubert Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany

Electrical discharge machining (EDM), widely used to fabricate medical devices, is applicable for antibacterial surface protection. Silver, transferred from tool electrode or powder suspended in the dielectric to the modified layer during the EDM process, significantly enhanced antibacterial properties of the modified surface. However, bacterial resistance to silver, which was widespread in clinical, still posed challenges for the modified surfaces containing silver. Zinc, owing to its strong antibacterial effects and no challenge related to Zn-resistant bacteria hitherto reported in clinical, was therefore used as tool electrode material to modify Ti6Al4V surfaces during the EDM process. Discharge energies up to 170 µJ with different polarities were applied in the EDM milling process using deionized water-based dielectric fluid. Results show that discharge energy and polarity play a vital role in chemical composition and roughness of the modified surfaces as well as material removal rate and tool wear rate. The surfaces containing zinc contents up to 28 % can be generated. The use of a low energy generates zinc-rich surfaces with less micro-cracks. The EDM process using zinc tool electrode shows a promising potential for antibacterial surface modification of medical devices.

关键词： EDM Zinc electrode Medical device Antibacterial surface

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Developments in Powder Mixed EDM and its perspective Application for targeted Surface Modification 15

Developments in Powder Mixed EDM and its perspective Applica...

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

作者： Schubert, Andreas Bui, Viet D. Schaarschmidt, Ingo Berger, Thomas Martin, André Chemnitz University of Technology Professorship of Micromanufacturing Technology Reichenhainer Strasse 70 Chemnitz09107 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

Although widely studied over the few decades, there are conflicting theories on the discharge mechanisms of powder mixed electrical discharge machining (PMEDM). Additionally, the dielectric flow plays a vital role in the distribution of powder particles in the machining gap, which significantly affects the powder deposition to the modified surface. In this paper, the literature on PMEDM surface modification is thoroughly reported. The conflicting mechanisms and the effects of PMEDM main machining conditions, such as powder and electrical parameters on improving mechanical and antibacterial properties as well as biocompatibility of the surface, have been discussed. To verify the separation mechanism of the discharge in PMEDM, single discharge investigations have been performed when silver nano-powder is mixed into the hydrocarbon-based dielectric fluid to modify Ti6Al4V surfaces. Surface topography, chemical composition as well as the deposited silver content and distribution over the crater surface when using positive and negative polarities are analyzed and discussed. Current waveforms of PMEDM and EDM without powder at varying discharge energies as well as with and without ultrasonic vibration assistance are recorded and analyzed. For the transfer of fundamental results to a perspective application, CFD simulation is used to calculate the flow field of the dielectric fluid and analyze the velocity and distribution of the nano-powder within the working gap of a setup with internal flushing. The results show that PMEDM is a potential technology for machining medical devices with simultaneous antibacterial surface modification. © 2022 The Authors. Published by Elsevier B.V.

关键词： Titanium alloys

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Robotic Visual Servoing for Tracking Structureless Moving Parts

Robotic Visual Servoing for Tracking Structureless Moving Pa...

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Iberian Robotics Conference (ROBOT)

作者： Christian Schroder Marco Schumann Rico Loser Philipp Klimant Martin Dix Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Professorship Virtual Technologies Hochschule Mittweida - University of Applied Sciences Mittweida Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz Germany

ISBN: (数字)9798350376364

ISBN: (纸本)9798350376371

The European Union has committed to achieving the 1.5-degree Celsius limit set by the Paris Climate Agreement, emphasizing the necessity for substantial energy savings across various sectors, particularly in industry. This ambitious goal requires a delicate balance between reducing energy consumption and maintaining economic strength. Concurrently, there is a noticeable shift from mass production to mass customization, driven by the need for more flexible and adaptable manufacturing processes. Cognitive robotics emerges as a pivotal technology in this context, offering enhanced capabilities for flexible production lines. One significant advantage is the ability to assemble moving parts which optimizes cycle times and therefore contributes to energy savings. This paper presents a novel approach to object tracking using NC robot-based position control, demonstrating its potential to support the industry's transition towards more sustainable and efficient manufacturing practices. The image processing algorithm, which consists of a fused methodology merging an iterative 2D image registration and stereo vision-based point cloud registration, demonstrates the ability to track an object with a mean L2-error of 3.5 mm in a dynamic environment.

关键词： Industries Point cloud compression Service robots Heuristic algorithms Energy conservation Position control Production Visual servoing Object tracking Meteorology

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Data quality in environmental assessment methods - Implications for the operational management in manufacturing 31

Data quality in environmental assessment methods - Implicati...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Elsner, Juliane Brings, Hanna Sohnius, Felix Schmitt, Robert H. Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Aachen52074 Germany Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 Aachen52074 Germany

To implement environmentally sustainable, resource-efficient manufacturing, the quantification of the environmental impacts is a central task. This task requires suitable methods. Various lifecycle phases, including remanufacturing concepts, and the associated increasing complexity demand a change from static to dynamic assessment methods. Flexible changes must be considered. Thereby, data quality has a major impact on the subsequent assessment results. Though the available data amount in a manufacturing environment is constantly increasing, the influence of data quality on the respective method - and thus, the reliability of the results - remains a key issue. To address this problem, this paper investigates the necessary developments regarding data quality for environmental assessment methods in dynamically changing manufacturing settings. First, relevant data quality dimensions are identified. Subsequently, a cross-comparison of data quality dimensions and different approaches of environmental evaluation in manufacturing is developed. The necessary changes to data quality requirements in operational environmental assessments are derived. Finally, a concept for the improvement of data quality in dynamic assessments is proposed and discussed based on the use case of battery modules' remanufacturing. This paper contributes to the development of environmental assessment methods that are evolving from static, historical data-based evaluations to dynamic assessment tools of flexible productions. © 2024 Elsevier B.V.. All rights reserved.

关键词： Sustainable development

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Robot-based, sensitive mating of electrical connectors using automatically designed gripper jaws 57

Robot-based, sensitive mating of electrical connectors using...

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18th IFAC Workshop on Time Delay Systems, TDS 2024

作者： Gebauer, Daniel Roith, Alexander Dirr, Jonas Daub, Rüdiger Institute for Machine Tools and Industrial Management Technical University of Munich Boltzmannstraße 15 Garching85748 Germany Fraunhofer Institute for Casting Composite and Processing Technology Am Technologiezentrum 10 Augsburg86159 Germany

Designing suitable gripper jaws is crucial for automating complex assembly tasks, such as mating electrical connectors. In previous work, we developed a methodology for these kinds of workpieces to generate gripper jaws automatically with parameterizable clearance, which is a proven way for robust grasping. Since there is uncertainty about the resulting in-hand pose, this paper investigates whether a sensitive joining strategy can compensate for this to ensure robust mating of electrical connectors. We conducted 600 grasp and about 450 mating tests using multiple high-voltage electrical connectors and clearances. In most experiments, sensitive joining strategies compensate for the in-hand pose uncertainty. © 2024 The Authors.

关键词： Grippers

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AI-driven force torque control strategies for further automate flexible high-precision, contact-intensive assemblies

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Procedia CIRP 2024年 130卷 348-354页

作者： Yunqi Gu Ruth Maria Otto Martin Naumann Leutrim Gjakova Rico Löser Martin Dix University of Applied Sciences Munich Lothstr. 34 80335 Munich Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany Chemnitz University of Technology 09111 Chemnitz Germany

Robotic assembly processes are integral to industrial manufacturing, traditionally relying on pre-programmed sequences that exhibit limited adaptability to uncertain conditions. Recent advancements propose AI-enhanced vision systems as viable solutions to mitigate uncertainty in automated tasks. Despite the potential of vision, contact-intensive, high-precision assembly processes need customized force-torque feedback strategies to perform the task. Parametrization for setup and adaption of force-torque processes are time consuming, but decisive for quality. This work outlines an AI-driven force-torque control strategic solution for peg-in-hole assembly task, which employs object detection algorithm to grasp the workpiece and determine flexible assembly position, with force-torque-informed DNN algorithm for error correction in terms of position, and digital twin to monitor the process and collect virtual data.

关键词： Robotic Assembly Force-torque control Deep-Neural-Network Cognitive Robotics

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Enhancing Tool Wear Segmentation with LoRA-SAM and Point Prompts

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Procedia CIRP 2025年 134卷 705-710页

作者： Zongshuo Li Ding Huo Markus Meurer Miguel Panesso Welf-Guntram Drossel Thomas Bergs Manufacturing Technology Institute (MTI) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Str. 44 01187 Dresden Germany Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany

Automated optical measurement of cutting tools offers a rapid and direct approach to monitoring tool wear. While the Segment Anything Model (SAM) exhibits strong zero-shot generalization capabilities in typical scenarios due to its powerful image encoder and prompt engineering, it underperforms in tool wear segmentation because of its lack of domain-specific knowledge. In this study, an image dataset containing various tools with different prompts was initially established, and SAM was fine-tuned using Low-Rank Adaptation (LoRA) and Mixture-of-Expert (MoE) LoRA to incorporate domain-specific knowledge of tool wear. The results consistently show that both LoRA-SAM and MoE-LoRA-SAM significantly outperform the original SAM in tool wear segmentation with over 55% improvement. Additionally, using a combination of three prompt points is sufficient for accurate tool wear segmentation. This finding highlights the potential applicability of SAM in industrial scenarios.

关键词： Tool wear Deep learning Image segmentation SAM

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