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Clamping and substrate plate system for continuous additive build-up and post-processing of metal parts

Procedia CIRP 2020年 93卷 108-113页

作者： Moritz Wollbrink Semir Maslo Daniel Zimmer Karim Abbas Kristian Arntz Thomas Bergs Fraunhofer Institute for Production Technology IPT Steinbachstr. 17 52074 Aachen Germany FH Aachen University of Applied Sciences Goethestrasse 1 52064 Aachen Germany Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University Campus-Boulevard 30 52074 Aachen Germany

The manufacturing share of laser powder bed fusion (L-PBF) increases in industrial application, but still many process steps are manually operated. Additionally, it is not possible to achieve tight dimensional tolerances or low surfaces roughness. Hence, a process chain has to be set up to combine additive manufacturing (AM) with further machining technologies. To achieve a continuous workpiece flow as basis for further industrialization of L-PBF, the paper presents a novel substrate system and its application on L-PBF machines and post-processing. The substrate system consists of a zero-point clamping system and a matrix-like interface of contact pins to be substantially connected to the workpiece within the L-PBF process.

关键词： Additve manufacturing post-processing process chain substrate plate base plate clamping automatization

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Basic material and technology investigations for material bonded hybrids by continuous hybrid profile fabrication

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IOP Conference Series: Materials Science and Engineering 2021年第1期1140卷

作者： K Schubert M Gedan-Smolka A Marschner T Rietzschel K Uhlig D Löpitz D Wagner M Knobloch Leibniz-Institut für Polymerforschung Dresden e.V. (IPF) Hohe Straße 6 01069 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Reichenhainer Straße 88 09126 Chemnitz Germany

The development of multi-material hybrids by injection molding has been studied very intensively at the IPF in the past. For that, a material bonding between the different substrates was achieved by using a newly developed two-step curing powder coating material as latent reactive adhesive. The aim of the project 'Hybrid Pultrusion' was to perform a novel approach for the fabrication of material bonded metal-plastic joints (profiles) in a modified pultrusion process. Therefore, powder pre-coated steel coil is combined with a glass-fiber reinforced epoxy resin matrix. For initial basic studies, the impregnated fiber material has been applied on the pre-coated steel sheets using the Resin Transfer Molding process (RTM-process). It was proved via lap shear tests, that this procedure resulted in very high adhesive strengths up to 35 MPa resulting from the formation of a covalent matrix-steel bonding as well. In addition, the failure mechanism was subsequently studied. Furthermore, by adapting the successful material combination to the pultrusion process it was demonstrated that material bonded hybrids can be achieved even under these continuous processing conditions.

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Automation of Life Data Analysis Processes

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IOP Conference Series: Materials Science and Engineering 2021年第1期1140卷

作者： Jonathan Krämer Gregor Thiele Theresa Johanni Jörg Krüger Department for Industrial automation at the Institute for Machine Tools and Factory Management Technical University of Berlin Department for Process automation and Robotics Fraunhofer Institute for Production Systems and Design Technology

Life data analysis is an effective statistical process to gain information on the reliability of technical facilities. The Weibull analysis is a widely-used method for modeling the probabilities of different functional failures. For its application in modern manufacturing and maintenance processes, an automation of this analysis is expedient. An exemplary process of data collection and fitting of a parametric model with continuous time scale is analyzed in this article. Its automation with different statistic software tools is described and comparatively evaluated. With the ambition of minimizing manual effort in the process, a highly automated solution was developed in this research. We describe this self-implemented solution in 'R' and justify that this procedure automatizes the process more than the examined commercial implementations. The here presented work proves to be a practical real-time assistance, right now applied in aircraft maintenance.

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Life Cycle Engineering of future aircraft systems: the case of eVTOL vehicles

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Procedia CIRP 2020年 90卷 297-302页

作者： Sofia Pinheiro Melo Felipe Cerdas Alexander Barke Christian Thies Thomas S. Spengler Christoph Herrmann Institute of Machine Tools and Production Technology (IWF) Chair of Sustainable Manufacturing and Life Cycle Engineering Technische Universität Braunschweig Germany Battery LabFactory Braunschweig (BLB) Technische Universität Braunschweig Germany Institute of Automotive Management and Industrial Production Technische Universität Braunschweig Braunschweig Germany Fraunhofer Institute for Surface Engineering and Thin Films (IST) Germany

This paper introduces the first steps towards a general modelling framework for the integrated life cycle engineering (LCE) of future air transportation systems. The focus of analysis lies on the potential environmental implications of batteries powering electric vertical takeoff and landing aircrafts (eVTOLs), which have emerged as an option for urban air mobility to alleviate automobile traffic in cities. The impact of main influencing factors on the sustainability of eVTOLs is discussed, presenting the main modelling requirements for an LCE framework to accompany the transition towards a more sustainable air mobility.

关键词： Life Cycle Engineering Aviation VTOLs Batteries

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Bio-inspired control of automated stem cell production

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Procedia CIRP 2020年 88卷 600-605页

作者： Péter Egri Balázs Cs. Csáji Krisztián B. Kis László Monostori József Váncza Jelena Ochs Sven Jung Niels König Robert Schmitt Christian Brecher Simon Pieske Stephan Wein Centre of Excellence in Production Informatics and Control Institute for Computer Science and Control Kende u. 13-17 Budapest 1111 Hungary Fraunhofer Institute for Production Technology Steinbachstr. 17 Aachen 52074 Germany Laboratory for Machine Tools and Production Engineering (WZL) RWTH Aachen University Campus-Boulevard 30 Aachen 52074 Germany

The possible role of stem cells in medical treatments can hardly be overestimated. Today they are produced – almost without exemption – with significant human involvement using adaptive protocols that take the growth behavior of the biological material into account. Automated production platforms are being developed and tested in a number of research laboratories with the main goals of improving reproducibility, as well as increasing quality and throughput. However, automated stem cell production differs from the traditional manufacturing processes in (1) the inherent diversity of the products (stem cells), (2) their varying growth rates and process times, (3) the need for their regular observation and process adaptation, and, therefore, (4) for mixed-initiative production control. A distinctive feature of the domain is the symbiotic co-existence and co-evolution of the technical, ICT and biological ingredients in production structures. A challenging way to overcome these issues is the use of biologically-inspired control algorithms. In the paper the application of reinforcement learning is proposed for this purpose. As a first step, a digital simulation of the stem cell production was performed in order to generate patterns for the training process and to test the approach. In addition to the description of the concept, the paper also presents initial research results.

关键词： Stem cell production Digital simulation machine learning Reinforcement-based control Biological transformation

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Transferring life cycle engineering to surface engineering

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Procedia CIRP 2020年 90卷 557-562页

作者： Alexander Leiden Peter-Jochen Brand Felipe Cerdas Sebastian Thiede Christoph Herrmann Chair of Sustainabel Manufacturing and Life Cycle Engineering Institut of Machine Tools and Production Technology (IWF) Technische Universität Braunschweig Langer Kamp 19b 38106 Braunschweig Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Bienroder Weg 54 e 38108 Braunschweig Germany

Most surface finishing processes for metals are associated with a high energy demand and the use of chemicals with the potential impact on human- and eco-toxicity. However, surface finishing processes can lead to environmental and economic benefits in other life cycle phases by reducing friction, wear and corrosion. The application of life cycle engineering into surface engineering allows to understand these effects. This study provides a framework to assess environmental and economic effects of surface treatments on other life cycle phases. A case study illustrates the contribution of a surface finishing process for cutting inserts to the life cycle performance.

关键词： Life cycle engineering Surface engineering Sustainability

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Effects of process interruptions on the microstructure and tensile properties of AlSi10Mg parts manufactured by Laser-Based Powder Bed Fusion

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Procedia CIRP 2020年 94卷 182-187页

作者： Maximilian Binder Cheechau Leong Christine Anstaett Georg Schlick Christian Seidel Gunther Reinhart Fraunhofer IGCV (Research Institute for Casting Composite and Processing Technology) Am Technologiezentrum 10 86159 Augsburg Germany Department of Applied Sciences and Mechatronics University of Applied Sciences Munich Lothstr. 34 80335 Munich Germany Technical University of Munich Institute for Machine Tools and Industrial Management Boltzmannstr. 15 85748 Garching Germany

During the metal-based additive manufacturing process “laser-based powder bed fusion” (short: PBF-LB/M) interruptions can occur throughout the build job. These interruptions may be planned to produce hybrid parts, e.g., to insert components or electronics into the part or to adapt the manufacturing process itself. But interruptions can also be fault-induced, which can occur due to system failures, insufficient available powder quantities or poor component and process characteristics. Depending on duration, temperature and ambient atmosphere, these interruptions can have major influences on the component’s properties. The effects of a process interruption on the microstructure and the tensile properties for the material AlSi10Mg are to be presented within this work. In addition the impact of process interruptions on the mechanical properties of the tested components is shown.

关键词： process interruptions change of microstructure tensile properties additive manufacturing metal laser-based powder bed fusion

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Incremental sheet metal forming on the example of car exterior skin parts

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Procedia Manufacturing 2019年 29卷 105-111页

作者： Sören Scheffler Alexander Pierer Peter Scholz Sebastian Melzer Dieter Weise Zdeněk Rambousek Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany VÚTS a.s. Svárovská 619 Liberec XI-Růžodol I 460 01 Liberec Czech Republic

In this article, current, application-related investigations in the field of incremental sheet metal forming (ISF) will be presented and discussed. The main focus of the study will be on the chain of conceptual design, experimentation and subsequent work processes, right through to the final assembly of car exterior skin parts of a streamlined vintage concept car. This will be accompanied by a comparison and evaluation of different production technologies with regard to their economic efficiency, their real duration times and the specific boundary conditions for the manufacturing of just one part per geometry. The manufacturing processes at the centre of the study were: deep drawing, hydroforming and ISF (Two Point Incremental forming (TPIF) and rolling). Following the holistic discussion on the procedure and choice of processes, the TPIF is examined in detail using the example of the rear mudguards.

关键词： Incremental Sheet Metal forming Two Point Incremental forming Sheet Metal forming forming machine Design

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Wishbone made of hybrid aluminum foam sandwich

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Lightweight Design worldwide 2018年第2期11卷 36-41页

作者： Claudia Drebenstedt Camilo Zopp Alexander Hackert Lothar Kroll Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany TU Chemnitz Germany

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Modeling energy and resource use in additive manufacturing of automotive series parts with multi-jet fusion and selective laser sintering

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Procedia CIRP 2021年 98卷 358-363页

作者： Mathias Wiese Alexander Leiden Christopher Rogall Sebastian Thiede Christoph Herrmann Polymer Additive Manufacturing Center AUDI AG Auto-Union-Straβe 1 Ingolstadt 85045 Germany Chair of Sustainable Manufacturing and Life Cycle Engineering Institute of Machine Tools and Production Technology Technische Universität Braunschweig Langer Kamp 19b Braunschweig 38106 Germany Chair of Manufacturing Systems Department Design Production and Management University of Twente Drienerlolaan 5 Enschede 7522NB The Netherlands Fraunhofer Institute for Surface Engineering and Thin Films (1ST) Bienroder Weg 54 E Braunschweig 38108 Germany

With additive manufacturing (AM) becoming a competitive manufacturing process for low to medium production volumes, rapid manufacturing becomes an increasingly relevant manufacturing approach. However, regulations and customers demand more eco-efficient life-cycles of products. This requires engineers and designers to pre-select between productive AM processes like selective laser sintering (SLS) and multi-jet fusion (MJF), based on their expected environmental impact in series production. As SLS already debuted in the mid-1980s, researches broadly explored parts’ mechanical properties, energy and resource use. The multi-jet fusion (MJF) technology, introduced in 2017, delivers comparable part properties at considerably higher print speeds. However, its energy and resource use is still scarcely covered. To close this gap, this publication develops a model for evaluation of energy and resource utilization based on a case study with an automotive exterior series part using an EOS P396 SLS and a HP 4200 MJF machine. Data from measurements in energy and material consumption as well as the print job shows a good predictability and builds the basis for an environmental assessment. The derived model and its functional blocks allow estimation and comparison of sustainability for different use cases in rapid manufacturing with MJF and SLS. Despite the process similarities, results concerning greenhouse gas emissions and cumulative energy demand are different. The gained insights enhance pre-selection of manufacturing strategies, a suitable printing technology and the evaluation of AM processes during manufacturing according to sustainability aspects. Printer manufacturers and users may find this research insightful for improvements in sustainability and comparability of future AM processes.

关键词： Rapid manufacturing Energy efficiency Resource efficiency Additive manufacturing Automotive engineering Process modeling

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