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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Uhlmann, E. Polte, M. Bulla, B. Dambon, O. Dicke, C. Hocke, T. Thißen, K. Heper, M. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Son-x GmbH Aachen Germany

ISBN: (纸本)9781998999118

Ultraprecision machining is a key technology for manufacturing complex steel moulds with dimensional accuracies in sub-micrometer range for mass production of optical components using micro-injection moulding. According to the state of the art, during the machining of carbide-forming metals, such as steel alloys, used single crystal diamond tools suffer from excessive tool wear. In order to overcome this technological und economical limitation, ultrasonic-assisted ultraprecision machining is applied successfully in a broad range of industrial and scientifically applications. Based on the reduction of the contact time between the tool and the workpiece excessive chemical and related tribological tool wear can be avoided. Nevertheless, the cutting speed is strictly limited to deceed critical contact times. Therefore, the monitoring of the tool vibration characteristic and thus the process control is a major challenge and of current industrial and scientifically interest. To overcome these challenges a method for in-situ measurement of the ultrasonic vibration is currently being developed and first results are shown. Using the sophisticated ultrasonic system, developed by SON-X GMBH, Aachen, Germany, up to a frequency fUS= 100 kHz the application of a dedicated eddy current sensor enabled the determination of the real path lines and the exact position of the cutting edge during the whole process with a displacement amplitude AD= 1 µm. The results were subsequently verified by laser vibrometer measurements. As a result of the investigation, an elliptical path movement of the cutting edge in the longitude direction AD,y= ± 1.0 µm and in z-direction AD,z= ± 0.34 µm could be determined using a frequency fUS= 100 kHz. Based on this new measurement method, the vibration characteristic can be specifically varied and adapted to the application. In addition, a comprehensive scientifical knowledge of the process can be gained and used to improve tool wear models. © European Soci

关键词： Vibration analysis

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Software assisted clamping point classification and position optimization for the efficient flexibilization of carbody fixtures using mathematical geometry-based search algorithms

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Procedia CIRP 2021年 99卷 466-471页

作者： Rayk Fritzsche Robert Schaffrath Marcel Todtermuschke Head of group Assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Head of dep. Assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

The fraunhofer IWU has been developed specialized clamping robots for production of different car-models on one fixture. One of the challenges with universal clamping of different components is the contact point between part and clamping device. For the optimization of the clamping contours, a software was developed with which the geometries of the clamping points can be automatically analyzed and classified. With target search criteria, the clamping position on the component can be changed so that the clamping contours are geometrically simplified. Thus, a huge reduction in the complexity of the flexible clamping device is possible.

关键词： Body in white Automated device design Analysis software Optimization Product flexibility

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Exposure to industrial noise: Impacts on cognitive performance 50

Exposure to industrial noise: Impacts on cognitive performan...

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50th International Congress and Exposition of Noise Control Engineering, INTER-NOISE 2021

作者： Pereira, Luiz Henrique Mesa Casa Knöfel, Björn Troge, Jan Drossel, Welf-Guntram Klein, Marcel Hübelt, Jörn Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01087 Germany Mittweida University of Applied Sciences Technikumplatz 17 Mittweida09648 Germany

ISBN: (纸本)9781732598652

Research on the relation between exposure to noise and cognitive performance inside industrial environments is not as broad as on office environments. For a better understanding of the specific industrial noise problems, 23 participants performed arithmetic tests inside a hemi anechoic room while they were exposed to a sequence of sound from five typical industrial noise sources. The subjects also classified how annoying they perceived the noise signals. The effects of noise on the arithmetic test's performance of the 23 participants was found on accuracy and on velocity, although the p-values of a Student t-test are comparable high. Dividing the subjects into a group of more noise annoyed resp. a group of less noise annoyed participants revealed significant influences of the presence of noise compared to an initial test without noise. The more annoyed subjects exhibit a drop of accuracy (-4%, p=0.017) while the less annoyed subjects increase significantly their velocity in the test (+15%, p=0.001). Subjects that evaluated noise as more annoying performed worse in a final arithmetic test (under silence) after being exposed to the noises, indicating a possible cumulative effect of noise on performance. The findings provide a better insight in the cognitive behavior of people who are exposed to industrial noise. Hence, the study will proceed with the specific noise analysis of single industrial workplaces. © INTER-NOISE 2021 .All right reserved.

关键词： Testing

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Life Cycle Gates: Extending the concept of Virtual Quality Gates along circular product life cycles 56

Life Cycle Gates: Extending the concept of Virtual Quality G...

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56th CIRP International Conference on Manufacturing Systems, CIRP CMS 2023

作者： Wilde, A.-S. Tonn, K. Abraham, T. Herrmann, Christoph Institute of Machine Tools and Production Technology Technische Universität Braunschweig Langer Kamp 19b Braunschweig38106 Germany Volkswagen AG Wolfsburg38436 Germany Fraunhofer Institute of Surface Engineering and Thin Films Bienroder Weg 54E Braunschweig38108 Germany

Reaching a higher level of sustainability of a products life cycle became a strategic goal for many companies over the past years. To achieve that higher level of sustainability, the transformation of linear product life cycles (cradle to grave) into circular life cycles (cradle to cradle) in the context of a Circular Economy (CE) is one promising approach. However, implementing a circular life cycle results in higher requirements in defining the best fitted strategy at the end of each product use stage depending on economic, environmental and social factors. In order to cope these increased requirements, the whole product life cycle has to become more transparent. This transparency can be reached by a holistic digital representation and virtual quality control of all life cycle stages. To implement a virtual quality control in each stage and enable the monitoring and controlling of the whole life cycle, the concept of Virtual Quality Gates can be extended. Virtual Quality Gates divide a defined manufacturing chain into different virtual, quality-relevant decision points to check the product quality and ensure a defined quality state before further manufacturing steps are approved. This concept can be transferred to each life cycle stage to ensure a holistic optimization of the products life cycle quality and an optimized selection of a strategy at the end of each use stage. This paper presents a framework for the implementation of virtual quality gates into product life cycles. These extended quality gates are defined as Life Cycle Gates, which are virtual decision points to optimize a product life cycle. The demand and applicability of the concept is shown for a mechanical recycling process of automotive parts. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://***/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the 56th CIRP International Confe

关键词： Circular Economy Life Cycle Gates Life Cycle Technologies Virtual Quality Gates

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Framework for increasing sustainability of factory systems by generative layout design

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Procedia CIRP 2022年 105卷 345-350页

作者： Marian Süße Steffen Ihlenfeldt Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Chemnitz Germany

The structure of factory systems has a long-term impact on the productivity and performance of production systems. With an increasing relevance of decentral renewable energy sources, factory planning becomes more complex due to an increase of decision criteria and possible solutions, but ecological impacts are also growingly depending on early structure decisions. However, decisions during planning processes in industry are still based on experience, qualitative assessments and discussions. Thus, planning results may not exploit the potential of the available solution space, nor do they allow quantitative traceability of layout configurations. Generative Design (GD) gained popularity in topology optimization and building construction and provides promising opportunities for complex design tasks. Not least with the increasing relevance of Building Information Modeling (BIM) in manufacturing, new methods and technologies for optimization become available to factory planners. Hence, the paper describes options for enhanced decisions in sustainable factory layout planning. Therefore, it provides a quick overview on optimization and GD in layout planning as well as the relation towards BIM and sustainability assessment. Based on this, possible extensions of optimization targets and boundaries towards energy and sustainability-related criteria is elaborated. Afterwards, necessary and potential data acquisition with the openBIM-related Industry Foundation Classes (IFC) is discussed. The paper concludes with an outlook towards further investigations on the overlap of layout design, BIM and sustainability.

关键词： Factory Planning Sustainable development Generative design Building Information Modeling (BIM)

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Derivation of Solution Bundles in Hybrid Portfolios of Industrial Solution Providers in machinery Engineering

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Procedia CIRP 2024年 128卷 298-303页

作者： Michael Riesener Maximilian Kuhn Carsten Boßmann Sven Schümmelfeder Dennis Hertell Günther Schuh Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 52074 Aachen Germany

Companies in the machinery engineering sector are identifying increased demand from their customers for integrated solutions that consist of product, service and software elements tailored to the customers’ specific needs. The companies must therefore transform themselves from classic product providers into industrial solution providers. In addition to the opportunity to differentiate themselves from other competitors, the transformation of the business model to the distribution of customer-specific value propositions provides new revenue opportunities. Progressive digitization and the increasing integration of service and software elements in the value chain are considered to be key enablers of the transformation into an industrial solution provider. In order to realize the transformation successfully, it is necessary to plan the portfolio holistically on the basis of systematized customer requirements and the existing elements in the portfolio. This paper therefore presents a methodology for deriving suitable solution bundles to realize the value propositions. For this purpose, an integrated architecture of the solutions is created, a comparison of the solution elements with the customer requirements is performed, and finally, a staggering of the solutions in the portfolio is conducted.

关键词： Portfolio Planning Solution Provider Servitization

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Experimental analysis on the accuracy of two dimensional curved cuts in wire ECM 15

Experimental analysis on the accuracy of two dimensional cur...

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

作者： Sous, F. Heidemanns, L. Herrig, T. Klink, A. Bergs, T. Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen University Campus-Boulevard 30 Aachen Germany Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 Aachen Germany

The advantages of sinking ECM like productivity and high surface quality regardless of the mechanical workpiece characteristics are always challenged by increased costs for process development. These costs result from the necessity to design specific tools and complex electrolyte flow devices for each machining task. Instead of using a task specific tool, wire ECM uses a universal tool to perform 2.5 dimensional cuts. However, due to the concentration of the electrical field on edges, machining of small radii and sharp edges on macro scale geometries is challenging and the achievable accuracy with wire ECM needs further investigation. Therefore, this study presents the machining of two-dimensional curved cuts with wire ECM in workpieces made of Inconel 718. In particular, the influence of the wire diameter and various process parameters such as feed rate and working voltage on the achievable cutting radius is investigated. Furthermore, the cutting kerf and resulting machining offset of the machined radii cuts are analyzed. © 2022 The Authors. Published by Elsevier B.V.

关键词： Wire

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Comparative analysis of topology optimization versus material substitution: Is there a best method for vehicle weight reduction?

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Procedia CIRP 2024年 128卷 132-137页

作者： Gibson P. Chirinda Stephen Matope Philani Zincume Whisper Maisiri Andreas Sterzing University of Stellenbosch Private Bag X1 Matieland Stellenbosch 7602 South Africa North West University Private Bag X6001 Potchefstroom 2531 11 Hoffman Street South Africa Fraunhofer Institute of Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

The United Nations (UN) Sustainable Development Goal 13 focuses on taking urgent action to combat climate change and its impacts. Resource efficient production and strict emission regulations have made vehicle weight reduction a subject of great interest. Common lightweighting techniques include topology optimization and material substitution. The benefits include reduced raw material usage, low fuel consumption, and low carbon emissions. There is a gap in the complex balance of decision-making. If an engineer is faced with the option of topologically optimizing or materially substituting, is one method better than the other? This paper comparatively analyses these lightweight design strategies.

关键词： topology optimization material substitution lightweighting automotive industry

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Nonlinearity of balanced mems loudspeakers: Optical experiments and numerical modeling using time-harmonic signals 27

Nonlinearity of balanced mems loudspeakers: Optical experime...

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27th International Congress on Sound and Vibration, ICSV 2021

作者： Melnikov, Anton Michael, Stolz Wall, Franziska Kaiser, Bert Mrosk, Andreas Schuffenhauer, David Monsalve, Jorge Sergiu, Langa Schenk, Hermann A.G. Ehrig, Lutz Conrad, Holger Ahnert, Maik Schenk, Harald Fraunhofer Institute for Photonic Microsystems IPMS Dresden Germany Arioso Systems GmbH Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Brandenburg Technical University Cottbus-Senftenberg BTU Micro and Nano Systems Cottbus Germany

ISBN: (纸本)9788378807995

A recently introduced novel actuator class, called the nano electrostatic drive (NED), uses the electrostatic actuation to generate large deflections of elastic structures. The NED principle was recently successfully applied to create an all silicon loudspeaker based on micro-electro-mechanical systems (MEMS) technology. Such MEMS audio transducers cover the full frequency range required for high fidelity audio applications. High fidelity audio reproduction also demands minimizing harmonic distortions substantially below 1 %. A major advance in this direction is combining the NED principle with a push-pull driving scheme in a balanced design (BNED), eliminating even harmonics. The practical implementation of a BNED design is however demanding. The nature of the Coulomb force, the impact of stress stiffening and the large deformations required for generating high sound pressures, to name a few aspects, potentially contribute to the harmonic distortion and therefore need advanced experimental methods and simulation models to allow for an apt design. In this paper, we report first results of an experimental technique, combining an optical microscope with a high-speed camera, capable of analyzing the local details of the actuator movement at frame rates of 50,000 frames per second. Dynamic features, such as the excitation of harmonics and intermodulations become clearly visible. These experimental results are then used to scrutinize and refine our multi physics FEM simulations. © "Advances in Acoustics, Noise and Vibration - 2021" Proceedings of the 27th International Congress on Sound and Vibration, ICSV 2021. All rights reserved.

关键词： Loudspeakers

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Maturity Assessment for the Introduction of Predictive Quality Approaches in Production Environments

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Procedia CIRP 2024年 122卷 1053-1058页

作者： Robin Günther Robert H. Schmitt Laboratory for Machine Tools and Production Engineering WZL of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany Fraunhofer Institute for Production Technology IPT Steinbachstraße 17 52074 Aachen Germany

By integrating data-driven analysis methods into existing procedures, quality and failure management performance can be increased systematically. Linking product and process data with existing failure and quality knowledge offers significant potential for enhancing the continuous improvement of processes and products. Nevertheless, the potential of data-driven analysis still needs to be fully exploited. Despite the apparent advantages of analysis-oriented approaches, many companies are hesitant to implement such transformation projects because quantifying possible benefits is challenging. Thus, there is an economic risk due to the limited availability of resources, which must be utilized purposefully. An approach that allows the systematic identification and prioritization of promising use cases and reduces the risk of introducing data-based approaches is missing. This paper conceptualizes a model to evaluate the potential for introducing data-based analysis in production processes. A maturity assessment, consisting of four dimensions and seventeen sub-dimensions, is presented, which enables the identification of promising use cases for implementing data-based approaches. The conceptualized model is validated using an expert survey.

关键词： Maturity Assessment Project Management Predictive Quality, Failure Management Quality Management

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