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An assessment method of machine components for usage-based value creation in complex manufacturing systems

Procedia CIRP 2023年 120卷 225-230页

作者： Mohaned Alaluss Robin Kurth Anton Mauersberger Chris Drechsler Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Institute of Mechatronic Engineering Dresden University of Technology Helmholtzstr. 7a 01069 Dresden Germany

Rising demands on manufacturing technologies lead to an increase in the complexity of corresponding machines and systems. This complexity acts as an obstacle to the development and realization of digital, usage-based business models for complex manufacturing systems. Particularly in the case of pay-per-use business models, it is necessary to monitor the actual machine load in operation to minimize the business risk on the operator and supplier side. This complicates the transition towards data-oriented value creation in manufacturing system environment. To overcome this challenge, a novel method to assess machine components regarding their potential to monitor the actual load and usage behavior of the whole manufacturing system is proposed. On this basis, the transparency and therefore confidence in digital, usage-based value creation like pay-per-use business models can be increased. The resulting approach is demonstrated by taking the example of a sheet metal forming press.

关键词： Methodology Manufacturing Forning Service Decision making

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Filling the semantics gap in industrial communication: Middleware+ for an internet of production 17th

Filling the semantics gap in industrial communication: Middl...

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17th IFAC Symposium on Information Control Problems in Manufacturing INCOM 2021

作者： Kiesel, Raphael Weiss, Arno Schmitt, Robert H. 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. © 2021 The Authors. This is an open access article under the CC BY-NC-ND license (http://***/licenses/by-nc-nd/4.0)

关键词： Interoperability

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Definition and Description of Matrix Production Systems

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Procedia CIRP 2024年 130卷 1875-1880页

作者： Daniel Ranke Michael Trierweiler Patricia Berkhan Marc Münnich Thomas Bauernhansl Fraunhofer Institute for Manufacturing Engineering and Automation IPA Nobelstr. 12 70569 Stuttgart Germany Institute of Industrial Manufacturing and Management IFF Nobelstr. 12 70569 Stuttgart Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

The industry’s use of adaptable production systems, such as matrix production, is increasing. However, these systems vary in their specific details. The lack of a unified definition, delimitation, and description hinders comparability and the transfer of lessons learned between different systems. This paper aims to propose a comprehensive definition of matrix production and differentiation between different implementation forms. To achieve this, the paper first examines existing approaches to define and describe production systems and their manifestations. Various frameworks and models have been proposed in the literature, but they often focus on specific aspects of production systems, neglecting the complexity of matrix production. The paper identifies common elements and challenges in defining and describing production systems by analyzing these approaches. A second investigation analyzes various existing descriptions of matrix production from the scientific literature. While some definitions focus on the organizational structure, others emphasize operational aspects. By synthesizing these definitions, the paper proposes a comprehensive definition of matrix production encompassing both dimensions. Furthermore, the paper includes cases of industrial implementations as a third investigation. These cases provide insights into the practical application of matrix production systems across different industries. The paper identifies common characteristics, challenges, and benefits associated with matrix production by analyzing these implementation examples. Finally, all three investigations are combined to create a unified definition and a complementary descriptive model. The proposed framework provides a systematic approach to define and describe matrix production systems. It allows for a better understanding and comparison of different implementations, facilitates the transfer of lessons learned, and promotes the exchange of best practices. This framework will enable r

关键词： Matrix Production Framework Definition

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Influence of engagement parameters on estimation of tangential cutting force using high-frequency process data of the machine tool 16

Influence of engagement parameters on estimation of tangenti...

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16th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2022

作者： Rytir, Michal Rönnecke, Jonas Hänel, Albrecht Kolar, Petr Ihlenfeldt, Steffen Czech Technical University in Prague Czech Institute of Informatics Robotics and Cybernetics Department of Industrial Production and Automation Jugoslávských partyzánu 1580/3 Prague160 00 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 Dresden01062 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. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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Direct laser interference patterning of cemented cutting tools 17

Direct laser interference patterning of cemented cutting too...

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Laser-based Micro- and Nanoprocessing XVII 2023

作者： Baumann, Robert Bouraoui, Yasmine Teicher, Uwe Selbmann, Erik Ihlenfeldt, Steffen Lasagni, Andrés Fabián Institute for Manufacturing Technology Technische Universität Dresden George-Baehr-Str. 3c Dresden01069 Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstraße 7a Dresden01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Fraunhofer Institute for Material and Beam Technology IWS Winterbergstraße 28 Dresden01277 Germany

ISBN: (纸本)9781510659230

Nowadays, improving processes sustainability has become a major topic for many manufacturers in metal processing industries. Next to the challenging rise of costs of raw material and tools, innovative and hard to process materials enter the market. Here, surface functionalization of cutting tools is devised as a convenient approach for reducing energy consumption as well as material losses. In this work, direct laser interference patterning (DLIP) is used for manufacturing periodic line-like structures with spatial periods of 5.5 µm on tungsten carbide. The texturing is applied on rake-flank faces of the cutting inserts, leading to texture depths up to 1.75 µm by controlling the amount of used laser pulses. Moreover, turning experiments under lubricated conditions carried out on Al 6061 T6 parts with structured and untreated tools are performed to investigate the tribological performance. In result, the used DLIP-functionalized cutting tools could effectively decrease machining forces up to 12 %. This is caused by the corresponding improvement in frictional and improved lubrication behavior at the tool/chip interface. Furthermore, the laser-processed tools generate thinner chips, which leads to a decrease in surface roughness by 31 % of the aluminum work piece. This work thus offers insight into the viability of improving cutting tools by laser surface micro patterning for upcoming innovative materials designed for improving tool wear resistance, energy efficiency and surface quality. © 2023 SPIE.

关键词： Tungsten carbide

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Improvement of cutting tools using laser-induced periodic surface structures for machining Aluminium alloy Al 6061 T6 17

Improvement of cutting tools using laser-induced periodic su...

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Laser-based Micro- and Nanoprocessing XVII 2023

ISBN: (纸本)9781510659230

Improving processes sustainability to address upcoming demands in metal processing industries such as innovative and hard to process materials has become a major topic for many manufacturers. Therefore, new tool material compositions or surface coatings are continuously developed. In this context, surface functionalization of cutting tools is foreseen as a convenient approach for minimizing material losses and thus energy consumption. In this work, laser induced periodic surface structures (LIPSS) are used for manufacturing quasi-periodic line-like patterns on tungsten carbide inserts. The textured tool surfaces show low spatial frequency LIPSS (LSFL) with spatial periods of 500 nm to 600 nm as well as high spatial frequency LIPSS (HSFL) with a spatial period of ~100 nm. Furthermore, the texturing is applied on rake and flank faces of the cutting tools with different offsets to the edge between 0 and 0.2 mm. The wettability analysis reveals a decrease of static contact angles for the used cutting fluid (CIMSTAR) from 38° to 12°, suggesting an improved cooling process during the machining step. In addition, turning experiments under lubricated conditions are carried out on Al 6061 T6 parts to investigate the tribological performance. The used LIPSS-functionalized cutting tools could effectively decrease the main machining forces by 10 %, the feed force by 21 % and the passive force by 9 %. Furthermore, the laser-processed tools generate thinner chips, which leads to a decrease in surface roughness by 31 % of the aluminum work piece. © 2023 SPIE.

关键词： Turning

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Injection mould measurement system for increasing manufacturing control and production quality 23

Injection mould measurement system for increasing manufactur...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, Eckart Trabasso, Luís Gonzaga Bolz, Robert Schweitzer, Luiz Hein, Christoph De Souza, Diego Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany SENAI Innovation Institute for Manufacturing Systems and Laser Processing Brazil

ISBN: (纸本)9781998999132

Tool and mould making is one of the most important sectors of industrial manufacturing. Currently, over a third of polymer products are manufactured by injection moulding or stamping. These processes are complex, as the melted or heated polymers are subject to thermomechanical changes. Since injection moulding and stamping are mostly used for mass production, process repeatability and quality of the final product are very important. Improper adjustments of process variables lead to various defects in the final product along with high amount of waste and rejects. The need for measurement and control of the process is mandatory. Frequently, the tool is not operated by the owner of the mold or the end user of the plastic components, respectively, but by an injection molding service provider within the supply chain. Consequently, it is impossible for the tool owner to trace the quality of parts regarding the parameters applied for processing. This is crucial information to connect parts outside the tolerances to the respective process characteristics. The increase of quality in the production is achievable through correlating the processing parameters applied with the produced components. Therefore, the aim of the research herein is to develop an autonomous sensor system for monitoring injection moulding and stamping processes. The system comprises an external component of the tool in order to record and document the parameters applied such as tool temperature, pressure, number of machined parts and geolocation among others. In conjunction with a connected laser marking system for injection moulding, the unique identification of the components and the unchangeable connection of the production parameters with an individual component is enabled. The direct technological added value is given by the fact that the customer is able to monitor the production at any time, any place, comparing the actual production with the agreed and specified conditions. Furthermore, this info

关键词： Injection molding

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Solving a multi-dimensional matching problem for grouping clamping points on car body parts

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Procedia CIRP 2022年 106卷 126-131页

作者： Lena Oberfichtner Antje Ahrens Rayk Fritzsche Valentin Richter-Trummer Marcel Todtermuschke Fraunhofer Institute of Machine Tools and Forming Technologies Reichenhainer Straße 88 09356 Chemnitz Germany

Modern car body production is faced by an increasing number of car models as well as individualizing options, which leads to the need for more adaptable assembly equipment, e.g. grippers and fixtures that can switch between models in a matter of seconds. Based on known clamping positions, automated jigs consisting of several clamps can already adapt to different part geometries. To enable an efficient flexible jig, exactly one clamp must be assigned to each clamping point of each model taking into account different optimization criteria. Therefore, clamping points need to be grouped across all different models in the planning phase. Grouping of clamping points e.g. in order to minimize adaptation time or tooling costs is usually performed manually. In this paper, the grouping optimization problem is formalized, and a mathematical algorithm is introduced to solve this multi-dimensional matching. The envisaged approach uses a greedy algorithm to get an initial solution, which is optimised to a technically feasible solution considering economical aspects. To conclude, a short evaluation of the achieved results - especially in comparison with expert based grouping - is given.

关键词： product flexibility flexible production adaptable jigs body in white automated design optimization analyzing software

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A Nonlinear Delay Model for Metabolic Oscillations in Yeast Cells

arXiv

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arXiv 2023年

作者： Chumley, Max M. Khasawneh, Firas A. Otto, Andreas Gedeon, Tomas Michigan State University United States Fraunhofer Institute for Machine Tools and Forming Technology IWU Germany Montana State University United States

We introduce two time-delay models of metabolic oscillations in yeast cells. Our model tests a hypothesis that the oscillations occur as multiple pathways share a limited resource which we equate to the number of available ribosomes. We initially explore a single-protein model with a constraint equation governing the total resource available to the cell. The model is then extended to include three proteins that share a resource pool. Three approaches are considered at constant delay to numerically detect oscillations. First, we use a spectral element method to approximate the system as a discrete map and evaluate the stability of the linearized system about its equilibria by examining its eigenvalues. For the second method, we plot amplitudes of the simulation trajectories in 2D projections of the parameter space. We use a history function that is consistent with published experimental results to obtain metabolic oscillations. Finally, the spectral element method is used to convert the system to a boundary value problem whose solutions correspond to approximate periodic solutions of the system. Our results show that certain combinations of total resource available and the time delay, lead to oscillations. We observe that an oscillation region in the parameter space is between regions admitting steady states that correspond to zero and constant production. Similar behavior is found with the three-protein model where all proteins require the same production time. However, a shift in the protein production rates peaks occurs for low available resource suggesting that our model captures the shared resource pool dynamics. Copyright © 2023, The Authors. All rights reserved.

关键词： Boundary value problems

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Influence of clearance and velocity during blanking on the fatigue behavior of cellulose-based biocomposites

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Procedia CIRP 2024年 125卷 54-59页

作者： Ronja Scholz Sven Winter Alexander Delp Tobias Breitfeld Verena Psyk Welf-Guntram Drossel Frank Walther Chair of Materials Test Engineering (WPT) TU Dortmund University Baroper Str. 303 D-44227 Dortmund Germany Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Reichenhainer Strasse 88 D-09126 Chemnitz Germany Institute for Machine Tools and Production Processes (IWP) Chemnitz University of Technology Reichenhainer Strasse. 70 D-09126 Chemnitz Germany

Cellulose-based biocomposites, such as Cottonid, are a promising class of materials to improve the carbon footprint of products during their service life. Cottonid has high technological potential due to its physical and mechanical similarities to engineering plastics and light metals. To replace traditional metallic materials in industry, cellulose-based semi-finished products need to be formed and cut. In particular, blanking is the most cost-effective and industrially common cutting method for metals. However, this study investigates the influence of various blanking process parameters on the quality and the fatigue strength of the resulting cutting edges of Cottonid. The presented results give insights on how the relationships between process parameters during cutting and resulting material properties known from conventional materials can be transferred to cellulose-based biocomposites like Cottonid. The relative clearance was varied between 4 and 10% and the cutting velocity between 0.05 and 10 m/s. It was evident that slower velocities and smaller clearances resulted in visibly better cutting edges. In order to relate this effect to the mechanical performance of Cottonid, new 3-point bend specimens were taken from the blanked strips for fatigue testing. It was found that the fatigue strength was significantly affected by the velocity and clearance. Further, similar to metallic materials, clean-cut (smooth area) and a fractured zone can be clearly distinguished. A good cutting edge quality results in a higher resistance of the Cottonid component against crack initiation at process-induced defects. The knowledge gained may enable an efficient cutting process for cellulose-based materials with higher fatigue strength in the future.

关键词： Cottonid Cellulose Shear Cutting High-Speed Impact Cutting Fatigue Cutting Edge Quality

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