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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Reinhardt, Heiner Mahdaviasl, Mahtab Prell, Bastian Mauersberger, Anton Klimant, Philipp Reiff-Stephan, Jörg Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Technical University of Applied Sciences Wildau Hochschulring 1 Wildau15745 Germany Virtual Technologies Hochschule Mittweida University of Applied Sciences Technikumplatz 17 Mittweida09648 Germany Institute of Machine Tools and Control Engineering Technische Universität Dresden Dresden01062 Germany

Implementing processes for traceability is required in various industries to assure product quality during manufacturing, provide evidence on required processing conditions or facilitate product recalls. Commonly, radio-frequency identification (RFID) or code recognition techniques (e.g. Data Matrix) are applied to track the flow of workpieces through a manufacturing system and link processing data accordingly. Although the analysis of tracking data is well-examined, we still see a gap in the research on the trade-off between data acquisition, data analytics and data quality. Here, we present a framework to increase the value of existing data by enabling data analytics while addressing common pitfalls and reducing the costs of data management. © 2024 Elsevier B.V.. All rights reserved.

关键词： Decision making

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Investigation of Surface Characteristics in Magnetic Field assisted Electrical Discharge Machining 7

Investigation of Surface Characteristics in Magnetic Field a...

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7th CIRP Conference on Surface Integrity, CSI 2024

作者： Bui, Viet D. Martin, André Berger, Thomas Schubert, Andreas Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

Electrical discharge machining (EDM) has demonstrated its promising potential for surface modification. The integration of materials from tool electrode or powder that is mixed into the dielectric fluid has proven to modify the workpiece surface to enhance its mechanical properties, realize antibacterial effects, or increase biocompatibility. Recent EDM studies showed that due to non-contact forces, properties of the modified surface such as roughness values and the thickness of modified layer were significantly influenced when using magnetic field assisted EDM. Consequently, in this study, an external magnetic field with a strength of 0.66 T is used to assist the material transfer from tool electrode to workpiece surfaces during the EDM process. Pure silver and copper tools with a diameter of 2 mm are used to modify surfaces of Ti6Al4V workpieces at a discharge energy of 125 µJ with different polarities. Results show that the assistance by magnetic field significantly increases the content of transferred material from tool electrode to the workpiece surface. Additionally, it increases material removal rate and reduces the modified layer thickness. Magnetic field assisted EDM is a potential technology for improving the efficacy of the EDM surface modification. © 2024 The Authors. Published by Elsevier B.V.

关键词： Titanium alloys

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Planar 3D-Printing and Intrinsic Heat Generation Thermoforming of a Fully Customizable Ankle Orthosis – A Feasibility Approach

Planar 3D-Printing and Intrinsic Heat Generation Thermoformi...

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Integrated Systems in Medical Technologies (ISMT)

作者： Johannes Knecht Marcel Müller Franziska Valerie Hagenauer Linda Weisheit Valentin Wilhelm Mauersberger Lukas Boxberger Biomechatronics Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Technical Design Technical University of Dresden Dresden Germany

ISBN: (数字)9798350375527

ISBN: (纸本)9798350375534

There is a wide spectrum of injuries and medical conditions that are treated with the use of orthoses. For better comfort fully customized orthoses are designed and manufactured via 3D-printing or thermoforming thermoplastic casts with a low glass transition and softening temperature nowadays. This study aims to print a planar orthosis design and then thermoform the orthotic blank with intrinsic heating to get the final customized design depending on patient's needs. After identifying possible thermoplastic polymers for the application with differential scanning calorimetry (DSC) to determine thermal properties, tensile testing for mechanical properties and peel-off testing to measure multi material printing adhesion, the final orthosis blank is printed using Wire-EncapsulatingAdditiveManufacturing to integrate heating wires into the structure and create the intrinsic ability of heat generation for the thermoforming process.

关键词： Heating systems Printing Temperature Wires Thermoforming Mechanical factors Softening Plastics Wearable devices Testing

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Antibacterial Surface Protection using Electrical Discharge Machining with Zinc Tool Electrode for Medical Devices 6

Antibacterial Surface Protection using Electrical Discharge ...

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6th CIRP Conference on BioManufacturing, BioM 2024

作者： Bui, Viet D. Martin, André Berger, Thomas Steinert, Philipp Schubert, Andreas Chemnitz University of Technology Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

Electrical discharge machining (EDM), widely used to fabricate medical devices, is applicable for antibacterial surface protection. Silver, transferred from tool electrode or powder suspended in the dielectric to the modified layer during the EDM process, significantly enhanced antibacterial properties of the modified surface. However, bacterial resistance to silver, which was widespread in clinical, still posed challenges for the modified surfaces containing silver. Zinc, owing to its strong antibacterial effects and no challenge related to Zn-resistant bacteria hitherto reported in clinical, was therefore used as tool electrode material to modify Ti6Al4V surfaces during the EDM process. Discharge energies up to 170 ìJ with different polarities were applied in the EDM milling process using deionized water-based dielectric fluid. Results show that discharge energy and polarity play a vital role in chemical composition and roughness of the modified surfaces as well as material removal rate and tool wear rate. The surfaces containing zinc contents up to 28 % can be generated. The use of a low energy generates zinc-rich surfaces with less micro-cracks. The EDM process using zinc tool electrode shows a promising potential for antibacterial surface modification of medical devices. © 2024 The Authors.

关键词： Deionized water

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Method for Evaluating and Identifying Energy-Efficient Process Chains for the Manufacturing of Press Hardening tools Based on the Deming Circle 18th

Method for Evaluating and Identifying Energy-Efficient Proce...

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18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Rautenstrauch, Anja Markov, Larisa Kräusel, Verena Faculty of Mechanical Engineering Institute for Machine Tools and Production Processes Professorship for Forming and Joining Technische Universitaet Chemnitz Reichenhainer Str.70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany

ISBN: (纸本)9783031288388

In response to rising energy demand, climate change and resource scarcity, the German government has set guiding targets for the transformation of energy systems by 2050. One goal is to increase energy efficiency in order to halve the demand for energy. An important instrument for increasing energy efficiency and reducing energy costs is the energy audit. By determining how much energy is consumed in which areas of the company, it is possible to identify where there is potential for savings. This paper presents an evaluation method for identifying energy-efficient process chains for the production of press hardening tools. The evaluation method is based on the Deming Circle and is intended to serve as a supporting tool for the energy audit. The method enables the analysis and evaluation of energetic variables of a process chain and is designed for manufacturing companies. © 2023, The Author(s).

关键词： Energy utilization

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Investigations on Case Hardening of an Additive Manufactured Steel 20MnCr5 (via PBF-LB/M)

Investigations on Case Hardening of an Additive Manufactured...

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作者： Mallow, S. Schmitt, M. Gebauer, M. Stockburger, R. Reich, M. Kessler, O. Materials Science University of Rostock Albert-Einstein-Straße 2 Rostock18059 Germany Fraunhofer Institute for Casting Composite and Processing Technology Igcv Augsburg Germany Fraunhofer Institute for Machine Tools and Forming Technology Iwu Dresden Germany Hanomag Härtol Lohnhärterei GmbH Gommern Germany

As an additive manufacturing process, powder bed fusion of metals using a laser beam (PBF-LB/M) enables the near-net-shape production of complex components in a single step. In combination with case hardening, it will thus be possible in the future to produce lightweight, functionally integrated transmission components characterized by high-strength surface layers with a sufficiently tough component core. However, the process-related new initial conditions resulting from very high solidification rates in PBF-LB/M may mean that case hardening of PBF-LB/M materials with standard parameters achieves different case hardening results than have been usual in the past. This hypothesis was investigated in the present work using the case hardening steel 20MnCr5 (material number 1.7147) after successful development of industry-relevant PBF-LB/M parameters. Besides the convincing results regarding microstructure, hardness and carbon depth profiles, case hardening with standard parameters led to irregular grain growth due to holding at high temperatures for several hours during carburization. © 2023 Walter de Gruyter GmbH, Berlin/Boston, Germany.

关键词： 3D printing

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Innovative actuating process for machining CFRP with force-controlled radial feed movement

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Procedia CIRP 2023年 119卷 669-674页

作者： Marie Peter Konstantin Sauer Joachim Regel Martin Dix Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

The use of lightweight materials such as carbon fibre reinforced plastics (CFRP) is increasing due to the demand for rising resource and energy efficiency, especially in the aerospace and automotive industries. Because of the high delamination tendency of these materials and their abrasive impact on the tool, the challenges in machining CFRP lie primarily in the drilling process and thus in the design of the drilling tool. In this paper, an innovative design of a drilling tool for machining CFRP with force-controlled radial feed movement of the cutting edges is presented. The aim of this tool is to create a tool axial force free process that uses a force-controlled radial feed motion, which matches the chip cross-section to the wear condition of the cutting edge. The tool concept is explained based on the functionality of the actuating process. Tests were evaluated with regard to process forces and drilling quality to show that the tool is capable of producing delamination-free bores in a tool axial force free process.

关键词： tool design adaptive control actuator drilling composite

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The Impact of Post-Processing Heat Treatment on the Magnetic Properties of Additively Manufactured Nd-Fe-B Magnets

SSRN

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SSRN 2024年

作者： Bittner, Florian Kumar Putta, Akhil Juerries, Florian Woodcock, Thomas George Drossel, Welf-Guntram Thielsch, Juliane Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Leibniz IFW Dresden Institute for Metallic Materials Dresden Germany Chemnitz University of Technology Institute for Machine Tools and Production Processes IWP Chemnitz Germany

The effect of post-process heat treatment on microstructure and magnetic properties by laser powder bed fusion (LPBF) additively manufactured Nd-Fe-B magnets was studied in dependence of heat treatment temperature and as built condition. The microstructure of the magnets in the as built condition is partly amorphous. The volume fraction of the amorphous phase depends on the LPBF manufacturing parameters of the magnets, and a subsequent heat treatment above 550°C leads to its crystallization with a corresponding, remarkable improvement in the magnetic properties. Higher heat treatment temperatures allow the precipitation of a-Fe in the microstructure, which deteriorates coercivity but increases remanence. Magnets with high initial volume fraction of amorphous constituents require higher heat treatment temperatures to obtain optimal magnetic performance and show an increased stability against overaging. © 2024, The Authors. All rights reserved.

关键词： Magnetic properties

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AI-driven force torque control strategies for further automate flexible high-precision, contact-intensive assemblies

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Procedia CIRP 2024年 130卷 348-354页

作者： Yunqi Gu Ruth Maria Otto Martin Naumann Leutrim Gjakova Rico Löser Martin Dix University of Applied Sciences Munich Lothstr. 34 80335 Munich Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany Chemnitz University of Technology 09111 Chemnitz Germany

Robotic assembly processes are integral to industrial manufacturing, traditionally relying on pre-programmed sequences that exhibit limited adaptability to uncertain conditions. Recent advancements propose AI-enhanced vision systems as viable solutions to mitigate uncertainty in automated tasks. Despite the potential of vision, contact-intensive, high-precision assembly processes need customized force-torque feedback strategies to perform the task. Parametrization for setup and adaption of force-torque processes are time consuming, but decisive for quality. This work outlines an AI-driven force-torque control strategic solution for peg-in-hole assembly task, which employs object detection algorithm to grasp the workpiece and determine flexible assembly position, with force-torque-informed DNN algorithm for error correction in terms of position, and digital twin to monitor the process and collect virtual data.

关键词： Robotic Assembly Force-torque control Deep-Neural-Network Cognitive Robotics

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Incremental micro-forming for surface finishing with piezoelectrically actuated hammering tool with coupling unit 21

Incremental micro-forming for surface finishing with piezoel...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Fiedler, Maik Kolouch, Martin Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9780995775190

machine hammer peening can be referred as an incremental mechanical surface treatment procedure, which can be realized by using various tools being based on various actuator principles. For the purpose of high productivity, a high-performance drive for generating vibrations in the tool of a high frequency is desired. Therefore, this paper presents a new hammer peening tool with a piezoelectric actuator. In order to facilitate this actuator principle for practical applications, a coupling unit is necessary being installed between the tool and the machine. This coupling unit insulates the process vibration at the machine (e.g. a machine tool or an industrial robot) and changes the operating mode of the hammer peening process from position controlled to force controlled. In such way, the accuracy of the positioning movement as well as the accuracy of the workpiece are not the issue anymore and the piezoelectrically actuated tool with a low stroke of 120 µm can be deployed for practical applications. This tool together with the coupling unit can reach hammering frequencies in the range from 800 to 1300 Hz. These frequencies enable higher feed rates and productivity of the hammer peening process than tools with pneumatic or electromagnetic actuators being available on the market. For the purpose of demonstration of the tool potential, some experimental tests are presented in this paper. Here, workpiece being milled like in die making were treated by the hammer peening process with the new tool. The surface were smoothed from Ra 1.18 μm to Ra 0.10 μm. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Piezoelectric actuators

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