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Impact of Cyber-physically enhanced manufacturing on the product requirement documentation in high-tech applications

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Procedia CIRP 2021年 102卷 210-215页

作者： Albrecht Hänel André Seidel Carl Willy Mehling Alexander Dementyev Karol Kozak Rudi Seidel Uwe Teicher Arvid Hellmich Welf-Guntram Drossel Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden 01187 Germany Technische Universität Dresden Center for Evidence-based Healthcare Dresden 01307 Germany Technische Universität Chemnitz Institute for Machine Tools and Production Processes Chemnitz 09126 Germany Technische Universität Dresden Institute of Mechatronic Engineering Dresden 01062 Germany

Conventional machining of high-tech parts and components is often associated with complex processes, long lead times and small to medium batch sizes. Obviously, there is great interest to shorten process development periods and increase process reliability. The transformation of conventional machines into cyber-physical production systems (CPPS) promises significant improvements here. In fact, CPPS allows real-time data acquisition and processing, enabling to target integrated process improvement and quality assurance. In the present work, a methodical procedure for structured data aggregation is introduced for a Cyber-physical enhanced machining process while being explained from a high-tech application point of view. This includes data generation, extraction, transfer and storage, data-consolidation, linkage, visualization and interpretation. Finally, the paper illustrates these aspects in terms of the effects on the “digital product requirements” in order to achieve the presented “analytics-ready” data model using the example of a high-tech application.

关键词： Digital Manufacturing System Modelling Process control Cyber-physical production

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High performance machining of continuous metal fibers with cascaded multi-stage profile tools

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Procedia CIRP 2021年 101卷 334-337页

作者： Uwe Teicher Tristan Lange Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden 01187 Germany Technische Universität Dresden Institute of Manufacturing Technology Dresden 01062 Germany Technische Universität Dresden Institute of Mechatronic Engineering Dresden 01062 Germany

Metallic fibers are essential for applications in the chemical industry, the automotive industry for brake pads and, more recently, for the air conditioning modules. The most productive process to date for producing continuous fiber lines with fiber cross-sections between 50 and 150 µm is the application of cascaded multi-stage profile tools for cutting from semi-finished wire products. One challenge is the development of a technology for highly ductile materials made of aluminium, which are used as fiber materials in the area of refrigeration adsorbers. Preliminary studies have shown that high cutting speeds are necessary for machining. For this reason, a highly manually operated machine system was advanced to meet the requirements of high cutting speeds and to integrated a process monitoring system. For the first time, experimental investigations were able to show the interrelationships between set technology values and the effective machining forces for this process. Further investigations were done using the example of aluminium alloys 5019 for an analysis of a control system for wire breakage detection on the basis of force sensors.

关键词： machining aluminium metal fiber optimization

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Force Modeling in Generating Gear Grinding Considering the Grinding Worm Topography

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Procedia CIRP 2022年 115卷 66-71页

作者： Patricia de Oliveira Löhrer Mareike Solf Jens Brimmers Thomas Bergs Laboratory of machine Tools and Production Engineering (WZL) from the RWTH University Campus Boulevard 30 Aachen 52074 Germany Fraunhofer Institute for Production Technology (IPT) Steinbachstraße 17 Aachen 52074 Germany

During generating gear grinding, a large portion of the energy generated is converted into heat that can flow into the gear. To better control the heat flowing to the gear, an energy distribution model was developed, which considers chip formation mechanisms of each grain of the grinding worm. The energy distribution calculation requires knowledge of micro-interaction characteristics of grains engaging with the gear. In this paper, a simulation model of generating gear grinding is developed, considering grains micro-interaction characteristics during the process. Ultimately, the calculation of energy distribution is performed, contributing to better knowledge of heat flow into the gear.

关键词： Grinding Gears Grinding Modeling Energy Modeling

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Empirical Studies on the Influence of Tool and Process Parameters on the Machinability in Plunge Milling of Lead-Free CuZn-Alloys

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Procedia CIRP 2022年 115卷 113-118页

作者： Kilian Brans Stefan Baier Daniel Schraknepper Thomas Bergs Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany

The element lead is used as an alloying element in CuZn-alloys with mass contents of up to m PB  = 4 % to improve machinability properties. Due to its toxicity, a number of legislative initiatives aim to reduce the lead content in CuZn-alloys. The reduction of lead in CuZn-materials leads to critical machinability problems and a reduction in productivity in a variety of machining processes. This also applies to the machining process plunge milling, where the central challenges are increasing cutting force components and unfavorable chip removal. In this publication, plunge milling of the lead-free CuZn-alloys CuZn37, CuZn42 and CuZn21Si3P is investigated in an analogy process. The objective of the analogy process was to identify relevant causes and influencing variables to reduce the cutting force components and to enhance geometrical accuracy. In this context, the tool geometry parameters face rake angle γ, cutting edge angle κ r and chamfered corner width b γ , as well as the cutting parameters feed f and cutting speed v c were varied. The influences of these parameters on the machinability were analyzed in depth regarding the cutting force components and the chip shape.

关键词： Lead-free CuZn-Alloys Brass Machining Plunge Milling Mass Production of Lead-Free Electrical Connectors

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Comparing the performance of a nested to a continuous evolution strategy with covariance matrix adaption for optimization of drilling EDM

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Procedia CIRP 2022年 113卷 220-225页

作者： E. Uhlmann J. Streckenbach M. Polte M. Osmanovic F. Schick Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Pascalstr. 8-9 10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Germany

Electrical discharge machining (EDM) is a complex manufacturing process where the correlation of the individual process parameters is not fully known. When introducing new materials or complex, individual geometries in EDM, a satisfactory vector of parameters for the process must be found. This challenge is often encountered in the aerospace industry as well as in mold and tool making. One previously successful method to tackle this challenge is the stochastic optimization procedure Evolutionary Strategy (ES). Utilizing an appropriately chosen objective function, the search for a suitable vector of input parameters may be formulated as a mathematical minimization problem over the parameter space. The ES with a covariance matrix adaption (CMA) was utilized to sample from this parameter space in a stochastic manner. Examining the impact of the CMA within an ES is a promising way to gain better insight into the performance of ES. For this purpose, a vector of input parameters was optimized for a drilling EDM process with a comma and a nested comma ES with CMA. It was found that the comma ES led to a reduction in erosion duration tero of 38 % compared to the initially chosen parameters and the nested comma ES led to a reduction in erosion duration tero of 27 % compared to the same initial parameters. The additional information stored in the covariance matrix enables the ES to find a local optimum of the parameter vector faster and more consistently. This fact is verified by use of visualizations of the covariance matrix on a two-dimensional subspace. From these findings it can be concluded, that for the application of the ES to the optimization of EDM processes the CMA should be performed continuously over all generations as opposed to resetting this matrix after a number of generations.

关键词： Electrical-discharge machining Evolution strategy Optimization

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Function oriented biological transformation of a lubrication process system

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Procedia CIRP 2022年 110卷 26-31页

作者： Johanna Hagen Robar Arafat Tim Abraham Christoph Herrmann Fraunhofer Institute for Surface Engineering and Thin Films IST Bienroder Weg 54E 38108 Braunschweig TU Braunschweig Institute for machine tools and production technology IWF Langer Kamp 19b 38106 Braunschweig

In the priority model of sustainability, ecology is listed as the most important category of sustainability. A main goal is the decrease of carbon dioxide and other emissions to the environment. To tackle this challenge, the so called biologisation of manufacturing is identified as one lever for sustainability. In this paper, the example of a cooling lubricant system is considered and how this can be biologically transformed into a self-sufficient, fully-fledged process system that meets the requirements of a biologically transformed manufacturing system. To reach this objective, a present state of cooling lubricant systems, the weak points and optimization potential is presented. For the biologisation, various strategies are collected and categorized for implementation into lubricant systems. Further, the biologisation approaches are combined into a holistic concept by identifying synergies and interactions. The last step is a detailed elaboration and evaluation of transformation strategies.

关键词： process systems sustainability biologisation bio economy cutting fluids self-sufficient processes

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Retrieving properties of manufacturing systems from traceability data for performance evaluation and material flow simulation 54

Retrieving properties of manufacturing systems from traceabi...

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54th CIRP Conference on Manufacturing Ssystems, CMS 2021

作者： Reinhardt, Heiner Münnich, Marc Prell, Bastian Arnold, Roman Krippner, Fabian Weber, Marek Seifert, Frank Putz, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Technical University of Applied Science Wildau Hochschulring 1 Wildau15745 Germany Volkswagen Sachsen GmbH Motorenwerk Chemnitz Kauffahrtei 47 Chemnitz09120 Germany Chemnitz University of Technology Straße der Nationen 62 Chemnitz09111 Germany

The operation of manufacturing systems is increasingly accompanied by data-driven continuous improvement processes and product traceability is required. Commonly, radio-frequency identification (RFID) technology is applied to track the flow of a uniquely-identifiable workpiece along various stations or waypoints within a factory. Based on an automotive use case, this paper describes how to analyze the resulting traceability data in order to identify several properties of a manufacturing system. The acquired knowledge can support performance evaluation and facilitate model building for material flow simulation as a foundation for digital twins and cyber-physical production systems. © 2021 Elsevier B.V.. All rights reserved.

关键词： Knowledge management

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Diamond coatings for advanced cutting tools in honing and grinding

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Procedia CIRP 2022年 108卷 589-594页

作者： S. Baron T. Tounsi J. Gäbler G. Mahlfeld C. Stein M. Höfer V. Sittinger H.-W. Hoffmeister C. Herrmann K. Dröder Fraunhofer Institute for Surface Engineering and Thin Films IST Bienroder Weg 54e 38108 BraunschweigGermany Institute of Machine Tools and Production Technology IWF Langer Kamp 19b 38106 Braunschweig Germany

In high-performance machining processes, the cutting tools are an essential factor with regard to the resulting quality of the manufactured components and the efficiency of the entire production chain. For the machining of advanced materials with high hardness and brittleness, tools combining cutting and abrasive machining with high wear-resistance were developed and investigated. Focusing on honing and grinding, the development of application-adapted tools, their coating characteristics, cutting behavior and their improvements of performance are presented. The results demonstrate high wear resistance and high material removal rates in combination with significantly reduced surface roughness.

关键词： high performance machining CVD diamond coating cutting tools

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Automated continuous fabrication of load-path adapted thermoplastic fiber prepregs 18

Automated continuous fabrication of load-path adapted thermo...

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18th European Conference on Composite Materials, ECCM 2018

作者： Gabriel, Felix Nebel, Daniel Fürst, Alexander TU Braunschweig Institute of Machine Tools and Production Technology Langer Kamp 19b Braunschweig38106 Germany Fraunhofer Institute for Machine Tools and Forming Technology STEX Department Fraunhofer Project Center Wolfsburg Hermann-Münch-Straße 2 Wolfsburg38440 Germany TU Braunschweig Institute for Engineering Design Langer Kamp 8 Braunschweig38106 Germany

ISBN: (纸本)9781510896932

Due to the lack of suitable production processes, most up-to-date composite components show a rather simple shell design with constant laminate build-up. Such designs are also known as "black metal" and lead to high costs and incomplete material utilization. In contrast, a special load-path adapted design with a high utilization of deployed materials can increase the lightweight degree and reduce costs at the same time. This paper proposes a first practical approach to provide the automated continuous fabrication of load-path adapted thermoplastic fiber prepregs in a calendaring process. For the complete impregnation of the textile, additional matrix is added in powder form in order to ensure a homogenous fiber volume ratio. An adjustable powder application system is proposed, which can be directly integrated into the calender and is able to follow the load-path adapted design routes provided as continuous semifinished material. A sensor-driven control strategy for the application module is presented in order to cope with the challenge of synchronization of the conveyed semifinished textile with the positioning and powder dosing mechanisms of the application system. © CCM 2020 - 18th European Conference on Composite Materials. All rights reserved.

关键词： Fabrication

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Guideline for Deployment of machine Learning Models for Predictive Quality in Production 55

Guideline for Deployment of Machine Learning Models for Pred...

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55th CIRP Conference on Manufacturing Systems, CIRP CMS 2022

作者： Heymann, Henrik Kies, Alexander D. Frye, Maik Schmitt, Robert H. Boza, Andrés Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 Aachen52074 Germany Laboratory for Machine Tools and Production Engineering WZL RWTH Aachen University Campus-Boulevard 30 Aachen52074 Germany Universitat Politècnica de València Camino de Vera s/n Valencia46022 Spain

Predicting product quality represents a common area of application of machine learning (ML) in manufacturing. However, manifold challenges occur during the integration of ML models into production processes. Therefore, this paper aims to provide a guideline for the deployment of ML models in production environments. Relevant decisions and steps for deploying models in predictive quality use cases are demonstrated. The results for each component of the proposed guideline - deployment design, productionizing & testing, monitoring, and retraining - have been validated with industry experts including exemplary implementations. © 2022 The Authors. Published by Elsevier B.V.

关键词： Artificial Intelligence Deployment machine Learning Manufacturing Predictive Quality Production

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