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MikroSystemTechnik Kongress 2023: Mikroelektronik, Mikrosystemtechnik und ihre Anwendungen - Nachhaltigkeit und TechnologiesouveranitatMicroSystems technology Congress 2023: Microelectronics, Microsystems technology and their Applications - Sustainability and technology Sovereignty

作者： Sharma, Priya Zumpe, Martin Stange, Maximilian Al Naser, Ibrahim Fraunhofer Institute for Machine Tools and Forming Technology IWU Germany

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Autonomous assembly and disassembly by cognition using hybrid assembly cells

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International Journal of Mechatronics and Manufacturing Systems 2023年第4期16卷 381-398页

作者： Frieß, Uwe Oberfichtner, Lena Hellmich, Arvid Fritzsche, Rayk Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Germany University of Technology Dresden Germany

Current political, economic, and ecological developments put severe pressure on European industries. Significant value chains depend uniliterally on single suppliers for many industrial resources including, raw materials, semi-finished goods as well as whole components. At the very same time, the European industry needs to get carbon neutral within an unprecedented short time frame. To address these challenges, flexibility, adaptivity[...], and resilience based on adaptive assembly and disassembly systems acting autonomously are key. Existing systems lack crucial capabilities as they focus on output volumes and economic criteria excluding part variance. Furthermore, these systems are unsuitable for small and medium batches due to the necessary investment. The paper presents a novel concept for hybrid-autonomous assembly and disassembly systems based on robot cells added to manual stations. A batch-individual allocation of sub-tasks to the autonomous robot-based system and the manual assembly on-site will lead to maximum flexibility while utilising the advantages of both. © 2023 Inderscience Publishers. All rights reserved.

关键词： machine learning

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Split CFD-simulation approach for effective quantification of mixed convective heat transfer coefficients on complex machine tool models 16

Split CFD-simulation approach for effective quantification o...

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

作者： Kumar, Tharun Suresh Geist, Alexander Naumann, Christian Glänzel, Janine Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

Estimation of mixed heat transfer coefficients on complex CFD-simulation models of 5-axis machine tools/ machining centers poses a whole new set of challenges. The enclosure around the machine which protects the user from chips and machining-process is also responsible for creation of an additional environment which has coolant supply, chips and moving air due to temperature changes and oil-emulsion exhaust. This results in a highly complex CFD model which has inner and outer environments along with multiphase fluid domains. The computational effort required is extremely large. The split-simulation approach divides the simulation model into internal and external environments. The natural convection is emphasized for external environment model and forced convection for internal multiphase environment model. This division significantly reduces the computational efforts involved by neglecting uninfluential solid bodies, cavities etc. and thereby the model size. The external and internal influences are mapped separately onto natural and forced convection coefficients using neural networks, which can be used to predict the combined heat transfer coefficients for any load cases within the training boundaries. The temperature fields obtained from split-simulation model are validated with thermography and temperature sensor readings taken from the machine in the form of a use-case study. © 2023 Elsevier B.V.. All rights reserved.

关键词： Genetic algorithms

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Joining of Laminated Core and Shaft of an Electric machine Rotor by Electromagnetic forming 14

Joining of Laminated Core and Shaft of an Electric Machine R...

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14th International Electric Drives Production Conference, EDPC 2024

作者： Psyk, Verena Fleischer, Linda Linnemann, Maik Bach, Mirko Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology Department Forming Technology Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (纸本)9798350356885

In the mobility industry and especially in case of electrically powered vehicles the implementation of lightweight powertrain components with high efficiency and minimum in-stallation space is of utmost importance. One approach to realize a particularly compact and light design is using a central motor, which is aligned with a planetary gearbox via coaxial (partly) hollow rotor shafts positioned one within the other to operate the left and right-hand wheels of the car. To enable further weight reduction, aluminium alloys might be considered for the hollow shafts instead of the conventionally used steel. When the electrical machine is assembled, the shafts must be firmly connected to the rotor core, which is typically made of laminated electrical steel core. Electromagnetic forming is a promising technology for joining tubular aluminium components with similar or dissimilar materials. In this paper, the suitability for the described joining task is investigated. For this purpose, an inductor specifically suitable for expanding a round tube into a non-rotationally symmetric cross section shape is suggested and the corresponding joining process is developed using coupled electromagnetic and structural mechanical simulation. Experimental validation is carried out using a technology demonstrator. © 2024 IEEE.

关键词： Epicyclic gears

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Overview of methodologies for the lifecycle management of smart product-service systems 34

Overview of methodologies for the lifecycle management of sm...

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34th CIRP Design Conference, CIRP 2024

作者： Mauersberger, Anton Reinhardt, Heiner Alaluss, Mohaned Mahdaviasl, Mahtab Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Nowadays, companies are operating in increasingly competitive and dynamic markets with rapidly changing customer demands. In order to meet these challenges, digitalization can be leveraged to achieve a transformation in product and service development. As a result, new concepts and methods are emerging, including smart product-service systems (smart PSSs). In combination with smart, connected products (SCPs), added value can be generated for several contracting parties. There are various methodologies available for the development and usage of smart services. However, these are insufficiently applied in practice. Here, an overview of methodologies supporting the various phases of the lifecycle of smart PSSs is presented. In doing so, a classification of these approaches is derived and discussed, while the need for further methodological research is outlined. © 2024 Elsevier B.V.. All rights reserved.

关键词： Smart manufacturing

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Numerical Method for Highly Accurate Prediction of the Vacuum Assisted Resin Infusion Process Based on Reusable Vacuum Bags with Integrated Flow Channels 1

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3rd International Conference on Innovation in Engineering, ICIE 2024

作者： Kafka, Jiri Meißner, Sven Falkenhain, Paul Scholz, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Theodor-Koerner-Allee 6 Saxony Zittau02763 Germany

ISBN: (数字)9783031626845

ISBN: (纸本)9783031626838

The current research introduces a recently devised vacuum assisted resin infusion technique (VARI) where the conventional multilayer vacuum system is substituted with reusable silicone vacuum bags featuring built-in resin flow channels. To create functionally integrated molds, an appropriate method for simulating the resin floe process needs to be devised. Numerical resin flow simulations based on Darcy’s law have been established for the design of conventional vacuum-assisted resin infusion processes, allowing accurate prediction of the infiltration of the textile reinforcement structures. The research has demonstrated that the traditional simulation method exhibits poor prediction accuracy, rendering it inappropriate for designing functionally integrated molds. To increase the prediction accuracy, a modified simulation approach with calibrated model parameters was developed. The developed simulation approach was successfully validated by further experimental investigations. It was demonstrated that a reliable simulation approach for the construction of functionally integrated silicone vacuum bags has been developed. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2024.

关键词： Fiber reinforced plastics

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Development of Guidelines for the Design of Functionally Integrated Molds for a Novel Vacuum Assisted Resin Infusion Process 2nd

Development of Guidelines for the Design of Functionally Int...

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2nd International Conference Innovation in Engineering, ICIE 2022

作者： Meißner, Sven Falkenhain, Paul Cordeiro, Rafael Scholz, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Saxony Zittau02763 Germany

ISBN: (纸本)9783031093814

In the present study, a newly developed vacuum assisted resin infusion process (FuVak) is described in which the conventional, disposable multilayer vacuum setup is replaced by reusable silicone vacuum hoods with integrated flow channels. In order to ensure high-quality impregnation of the fiberglass textile structure in a short time, while avoiding the use of disposable layers like flow aids, a suitable design of the flow channel geometry and their positioning on the vacuum hood must be determined. To study the effect of the channel cross-section, an experimental setup with varying geometries in laboratory-scale was designed, constructed, and tested. Optical detection of the flow front during the Infusion process and later examining of porosity distribution on the cured part were performed. The relationship between channel cross-section, flow speed and final part quality (porosity distribution) were determined and discussed. Based on this, an industry-scale, 2 m long part with higher complexity was fabricated with the novel process, validating the process ability to control of the flow front and quality of the composite. © 2023, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Silicones

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Computer-based design and development of a fully automated assembly of aircraft doors made of thermoplastic composite material 17

Computer-based design and development of a fully automated a...

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17th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2023

作者： Fritzsche, Rayk Jager, Erik Head of Group Adaptable Assembly Systems Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Scientific Employeeat Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

For production of aircraft doors using innovative lightweight materials, a fully automated assembly process was developed. Therefor a door structure of an overwing-exit-door is to be joined from thermoplastic composite material components. The innovative material enable the use of new joining concepts. The assembly process was virtually simulated in order to forecast production time, process sequence, provision of operating resources and investment costs. Relevant manufacturing equipment was designed and accessibilities of the clamping and joining tools as well as collision areas were determined and optimized. To quality management, process control concept was developed with which geometric deviations of the components can be automatically compensated. © 2024 Elsevier B.V.. All rights reserved.

关键词： Process control

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Combined Evaluation of Digitalization and Sustainability Maturity of Small and Medium Sized Enterprises 19th

Combined Evaluation of Digitalization and Sustainability Mat...

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19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Münnich, Marc Schönfelder, Annabell Stange, Maximilian Süße, Marian Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

ISBN: (纸本)9783031774287

Sustainability and digitalization are of high importance for companies to stay competitive and cope with market requirements from internal and external stakeholders. Especially the current changes in reporting standards and frameworks increase pressure to quickly adapt internal processes and acquire the relevant data. In this context, Industry 4.0 (I4.0) is discussed to enable companies to also foster sustainability. But many small and medium sized enterprises (SME) lack of experience and capacity and need support from experienced partners to develop suitable strategies and implement technologies. Appropriate support comprises general guidance through these domains and an evaluation of current and desired state of expertise to choose suitable actions. Maturity models (MM) are well-established to initiate and support the transformation of corporate structures. There are many models available that support digital and sustainable transformation, but almost no models are available that include both dimensions what results in decoupled developments in these domains. Hence, this contribution introduces a combined model for both domains and systematically describes the extension of an existing digitalization MM (DMM) that also considers rebound effects. The MM is tested within an industrial context use case. The results are evaluated and discussed for further development of the model and workflow. © The Author(s) 2025.

关键词： Sustainable development goals

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Manufacturing of complex NiTi geometries with LPBF and adapted scanning strategies

Manufacturing of complex NiTi geometries with LPBF and adapt...

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2024 International Conference on Shape Memory and Superelastic Technologies, SMST 2024

作者： Herzig, Sandra Eckert, Medardus Müller, Bernhard Weisheit, Linda Thielsch, Juliane Drossel, Welf-Guntram Holtzhausen, Stefan Koch, Peter Schleyer, Mario Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Dresden University of Technology Dresden Germany Fraunhofer Institute for Mechanics of Materials IWM Freiburg Germany

ISBN: (纸本)9781627084840

NiTi shows a very promising combination of properties among different shape memory alloys. However, machining NiTi is a challenging task, making the manufacturing of complex geometries hard to nearly impossible using conventional manufacturing routes. As a result, the material’s full potential of the material has not been harnessed. The pseudoelastic properties of bulk NiTi are restricted to an 8 % strain [1]. Additive manufacturing of NiTi using laser powder bed fusion (LPBF) has been demonstrated as a successful alternative production route [2], capable of exhibiting pseudoelastic behavior even in the as-built state [3]. Existing literature has shown that modifications of the processing parameters can change the properties of Ni-rich NiTi significantly [4], which can be utilized intentionally to control the pseudoelastic properties in LPBF-manufactured NiTi. The fabrication of porous and lattice structures using LPBF allows to attain specific properties. This is achieved not only through the adjustment of the laser parameters and scanning pattern but also by enabling the creation of specifically tailored feature sizes and geometrical designs, such as unit cell design, the number and distribution of unit cells, and gradation. These geometrical structures go beyond the conventional unit cell designs (like the bcc unit cell), and when combined with the unique material behavior, they can result in extraordinary properties. It is possible to create a programmable material whose behavior can follow a logical description. The influence of lattice structure geometry and manufacturing parameters on the mechanical and functional performance will be discussed in the following. In addition, we present a structure whose stiffness behavior follows an if-then-else statement regarding to the effective strain and permits an effective strain exceeding 20 % without failure. The structure can be implemented in a planar clamping element which allows an adjustment to different shapes b

关键词： Titanium alloys

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