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Coupled CFD model of tool environment and workspace to determine the convective heat transfer in jet cooling of milling processes in machine tools

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Procedia CIRP 2025年 133卷 280-285页

作者： Steffen Brier Alexander Geist Janine Glänzel Christian Naumann Joachim Regel Martin Dix Steffen Ihlenfeldt Chemnitz University of Technology Professorship Production Systems and Processes Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Technical University Dresden Institute for Machine Tools Development and Adaptive Controls Helmholtzstraße 10 01069 Dresden Germany

The responsible use of resources is an essential part of the manufacturing of industrial products. This includes the economical use of cooling lubricant and requires precise knowledge of the cooling mechanisms and their effect on the accuracy of the machine tool and thus the thermal error. A temporal and spatial resolution of the dynamic coolant flow near the tool and in the entire workspace in a single model would require a large simulation time. Therefore, a composite model was developed, that consists of a near-tool model and a larger surrounding workspace model. The required static near-tool cooling lubricant distribution is obtained via data discretization methods from a separate static simulation that resolves the turbulence of the cooling lubricant created by the tool rotation. The identified coolant distribution is integrated into a CFD near-tool model (with simplified tool geometry) which is coupled with a surrounding CFD workspace model. The workspace model is thus able to identify the effects of the coolant wetting on the machine surface temperature and finally, using thermo-elastic FEM simulations, on the resulting thermal error. This approach allows the composite model to simulate the entire workspace with reduced simulation effort and map the coolant-influenced heat transfer coefficients on the machine surface.

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An assessment method of machine components for usage-based value creation in complex manufacturing systems

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Procedia CIRP 2023年 120卷 225-230页

作者： Mohaned Alaluss Robin Kurth Anton Mauersberger Chris Drechsler Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Institute of Mechatronic Engineering Dresden University of Technology Helmholtzstr. 7a 01069 Dresden Germany

Rising demands on manufacturing technologies lead to an increase in the complexity of corresponding machines and systems. This complexity acts as an obstacle to the development and realization of digital, usage-based business models for complex manufacturing systems. Particularly in the case of pay-per-use business models, it is necessary to monitor the actual machine load in operation to minimize the business risk on the operator and supplier side. This complicates the transition towards data-oriented value creation in manufacturing system environment. To overcome this challenge, a novel method to assess machine components regarding their potential to monitor the actual load and usage behavior of the whole manufacturing system is proposed. On this basis, the transparency and therefore confidence in digital, usage-based value creation like pay-per-use business models can be increased. The resulting approach is demonstrated by taking the example of a sheet metal forming press.

关键词： Methodology Manufacturing Forning Service Decision making

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Efficient evaluation of the acoustical behavior of gearboxes with various gear blanks using frequency based substructuring 27

Efficient evaluation of the acoustical behavior of gearboxes...

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27th International Congress on Sound and Vibration, ICSV 2021

作者： Hensel, Eric Bräunig, Jan Troge, Jan Stapf, Tom Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology Dresden Germany

ISBN: (纸本)9788378807995

In several industrial branches, the acoustical behavior of gearboxes plays a major role. In most cases, the transmission's noise is perceived as an annoying sound, the so-called gear whine with narrow-band spectral components. This tonal noise is caused by the gear mesh and is mainly dependent on the number of teeth as well as the corresponding rotational speed. In combination with the frequency-dependent structure-borne and airborne sound transfer paths of the gearbox and its subsequent systems, different speeds may lead to resonant system response due to the variable excitation frequencies. The purpose within the design process of gearboxes is the identification of such critical acoustic load conditions and the deviation of adequate measures to improve the acoustical behavior. As well known from other applications, the frequency based substructuring provides a methodology to evaluate the vibrations of a system consisting of different subsystems represented by frequency-dependent admittance functions. A main advantage of this method is that the single subsystems are independent from the mounting conditions. Within the present paper, the frequency based substructuring approach is used to evaluate the dynamic behavior of a single-stage gearbox with different gear blanks but equal tooth geometries. After a short introduction of the corresponding theory, the application of the frequency based substructuring method on gearbox dynamics is shown. In a next step, the simulation results are compared to experimental data obtained by test bench measurements with two different types of blanks - a reference model with no modifications as well as a gear with a metal foam core to change the stiffness of the gear blank significantly. Finally, the influences of different gear blanks are shown and discussed based on simulation results. © "Advances in Acoustics, Noise and Vibration - 2021" Proceedings of the 27th International Congress on Sound and Vibration, ICSV 2021. All rights re

关键词： Metals

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Increasing Resilience of Production Systems by Dynamic Context Modelling and Process Adaption 16

Increasing Resilience of Production Systems by Dynamic Conte...

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

作者： Wunderlich, Tim Hansert, Jonas Koch, Sandro Heinrich, Robert Schlegel, Thomas Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany Karlsruhe University of Applied Sciences Moltkestr. 30 Karlsruhe76133 Germany Karlsruhe Institute of Technology Am Fasanengarten 5 Karlsruhe76131 Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden01062 Germany

The requirements for cyber-physical production systems (CPPS) grow steadily, leading to increased complexity of such systems. To address issues due to reconfiguration or failures, we present an approach to creating a context model of the CPPS components during runtime and to detect deviations from the planned production processes. Furthermore, we present a concept for modelling production processes that allows for dynamic process adaption during runtime. We then utilize this process adaption and the context model to cope with unforeseen failures and increase the resilience of the system. Finally, we evaluate the feasibility of our approach by applying it to an Industry 4.0 production system. © 2023 Elsevier B.V.. All rights reserved.

关键词： Dynamics

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Characterization of 3D printed polymer mounts in translational and rotational DOF 30

Characterization of 3D printed polymer mounts in translation...

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30th International Conference on Noise and Vibration Engineering, ISMA 2022 and 9th International Conference on Uncertainty in Structural Dynamics, USD 2022

作者： Troge, J. Georgi, T. Hensel, E. de Klerk, D. Graf, M. Burkhardt, M. Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany VIBES.technology Molengraaffsingel 14 Delft2629JD Netherlands Fraunhofer Institute for Chemical Technology ICT Joseph-von-Fraunhofer Str. 7 Pfinztal76327 Germany

ISBN: (纸本)9789082893151

Mounts are important transfer elements to isolate structure-borne sound from a source to a receiver. The dynamic transfer behavior of a mount can be described using frequency dependent dynamic stiffness and damping. For determination of these parameters, a mount can be abstracted as a two-port element. The stiffness matrix of this element includes input, output and transfer stiffnesses for translational and rotational DOF. Especially the measurement of rotational DOF can be a challenge. A promising approach for this is the Virtual Point Transformation. Hereby, the dynamic behavior in a virtual point of a structure is calculated by combining signals from several vibration sensors. This approach was used to determine stiffness matrices of different polymer mounts, which were manufactured using a 3D printing process to ensure direction-dependent dynamic properties. This paper deals with the practical implementation of the method as well as the presentation of the results and deviations of the dynamic transmission behavior of the polymer mounts. © 2022 Proceedings of ISMA 2022 - International Conference on Noise and Vibration Engineering and USD 2022 - International Conference on Uncertainty in Structural Dynamics. All rights reserved.

关键词： Stiffness matrix

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A Nonlinear Delay Model for Metabolic Oscillations in Yeast Cells

arXiv

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arXiv 2023年

作者： Chumley, Max M. Khasawneh, Firas A. Otto, Andreas Gedeon, Tomas Michigan State University United States Fraunhofer Institute for Machine Tools and Forming Technology IWU Germany Montana State University United States

We introduce two time-delay models of metabolic oscillations in yeast cells. Our model tests a hypothesis that the oscillations occur as multiple pathways share a limited resource which we equate to the number of available ribosomes. We initially explore a single-protein model with a constraint equation governing the total resource available to the cell. The model is then extended to include three proteins that share a resource pool. Three approaches are considered at constant delay to numerically detect oscillations. First, we use a spectral element method to approximate the system as a discrete map and evaluate the stability of the linearized system about its equilibria by examining its eigenvalues. For the second method, we plot amplitudes of the simulation trajectories in 2D projections of the parameter space. We use a history function that is consistent with published experimental results to obtain metabolic oscillations. Finally, the spectral element method is used to convert the system to a boundary value problem whose solutions correspond to approximate periodic solutions of the system. Our results show that certain combinations of total resource available and the time delay, lead to oscillations. We observe that an oscillation region in the parameter space is between regions admitting steady states that correspond to zero and constant production. Similar behavior is found with the three-protein model where all proteins require the same production time. However, a shift in the protein production rates peaks occurs for low available resource suggesting that our model captures the shared resource pool dynamics. Copyright © 2023, The Authors. All rights reserved.

关键词： Boundary value problems

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A survey on sustainability approaches in manufacturing

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Procedia CIRP 2023年 116卷 101-106页

作者： Bastian Prell Heiner Reinhardt Anton Mauersberger Alexander Rauscher Jörg Reiff-Stephan Steffen Ihlenfeldt Technical University of Applied Sciences Wildau Hochschulring 1 15745 Wildau Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

Awareness about climate change has led to policies and regulations but also customer preferences favoring sustainable production. Thus, producing businesses are confronted by this, as they consume a large share of resources. Therefore, when producing, additional dimensions beyond commercial feasibility ought to be considered. Here, literature on sustainability from the field of engineering science is systematically searched and analyzed for approaches leading to actual recommendations for action. Hence, this bottom-up approach, incorporating the production engineers’ point of view, represents an inside view of how the topic of sustainability has arrived at production companies. The focus on commercial feasibility ensures high relevance to practice, as production needs to become both sustainable and competitive. Even though exemplary collections of different approaches addressing the topic of sustainability in production can be found in literature, novelty is provided by the structured manner literature was collected and the special focus on approaches leading to practice-relevant recommendations for action. Thus, a comprehensive overview of approaches applicable to the manufacturing domain is presented.

关键词： Eco-design methodology Economics Environment(al) Innovation management Manufacturing Production Sustainable development

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Filling the semantics gap in industrial communication: Middleware+ for an internet of production 17th

Filling the semantics gap in industrial communication: Middl...

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17th IFAC Symposium on Information Control Problems in Manufacturing INCOM 2021

作者： Kiesel, Raphael Weiss, Arno Schmitt, Robert H. WZL RWTH Aachen University Aachen Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Fraunhofer Institute for Production Technology IPT Aachen Germany

To enable interoperable communication between enterprise software and industrial assets, the Internet of Production reference model suggests a single platform for routing and data access. This Middleware+ must not only act as a central message broker but also meet the challenge of incompatible data models. However, its exact capabilities remain blurred. We first compile relevant technologies and standards to integrate. Definition of requirements and a software architecture proposal follow. Considering the heterogeneous degree of connectivity within producing companies, we then sketch the path to implementation based on maturity levels. The result is a distributed information system architecture ensuring the rigorous use of semantic information models throughout the entire lifecycle of a product. © 2021 The Authors. This is an open access article under the CC BY-NC-ND license (http://***/licenses/by-nc-nd/4.0)

关键词： Interoperability

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Dismantling and remanufacturing strategies in the automotive sector

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Procedia CIRP 2024年 122卷 695-700页

作者： Rico Haase Daniele Farioli Rene Selbmann Markus Werner Verena Kräusel Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany Politecnico di Milano Department of Mechanical Engineering 20156 Milan Italy

The contemporary recycling of automobiles takes place on a very baseline material level. In order to fundamentally improve the ecologic footprint of the vehicle, a wider application of remanufacturing strategies is intended. Following different recycling approaches ranging from direct reuse or refurbishment through remanufacturing until repurpose, a well-aimed dismantling followed by manufacturing processes adapted to the post-consumer components is mandatorily required. For use on an industrial scale, environmental efficiency and economic viability must be balanced well. Within the paper, possible remanufacturing technologies and necessary prerequisites such as input data are discussed. For the design of remanufacturing operations, material properties and geometric information are a crucial starting point. Seamless integration of the specific properties is intended to encourage wider utilization of pre-used components and materials. With reference to the well-established process design for metal forming operations, adapted material cards and curvature equivalence values are proposed. The approach is illustrated by a reforming operation, where a brake disc cover is remanufactured from a used car body roof.

关键词： circular economy automotive recycling dismantling remanufacturing secondary raw material pre-used components

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Micro-texture dependent temperature distribution of CVD diamond thick film cutting tools during turning of Ti-6Al-4V 6th

Micro-texture dependent temperature distribution of CVD diam...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Uhlmann, E. Schröter, D. Gärtner, E. Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute For Production Systems And Design Technology Ipk Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute For Machine Tools And Forming Technology Iwu Reichenhainer Str. 88 Chemnitz09126 Germany

Machining titanium alloys such as Ti-6Al-4V results in a high thermomechanical load on cutting tools and consequently short tool lifes. With respect to a necessary reduction of the resulting cutting tool temperatures, ultrashort pulse (USP) laser fabricated micro-textured rake faces offer direct supply of cooling lubricant into the cutting zone and lead to a reduced heat induction. As a result, micro-textured CVD diamond thick film cutting tools are also capable of machining high-performance materials due to reduced contact temperatures. In the scope of the research, the resulting temperature distribution for micro-textured rake faces will be compared under both dry and wet process conditions. Measurements show a reduction of the resulting cutting tool temperatures of ΔÏ't = 27.9 % using micro-textured cutting tools compared to non-textured cutting tools. A validated simulation provides valuable information about the contact temperatures enabling a specific development of the micro-texture geometry. As a result, a reduction of the contact temperature between chip and rake face by ΔÏ'T = 24.7 % was possible. © 2022 The Authors.

关键词： Turning

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