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

作者： Rytir, Michal Rönnecke, Jonas Hänel, Albrecht Kolar, Petr Ihlenfeldt, Steffen Czech Technical University in Prague Czech Institute of Informatics Robotics and Cybernetics Department of Industrial Production and Automation Jugoslávských partyzánu 1580/3 Prague160 00 Czech Republic Fraunhofer Institute for Machine Tools and Forming Technology IWU Department of Production Digital Twin Nöthnitzer Straße 44 Dresden Germany Technische Universität Dresden Institute of Mechatronic Engineering Chair of Machine Tools Development and Adaptive Controls Dresden01062 Germany

The machining of high-value products needs advanced quality control to avoid the risk of expensive follow-up operations performed on parts with unacceptable quality. This situation requires the in-process or close to in-process control of the machining operation. The tangential cutting force is a parameter that characterizes the force interaction between the specific workpiece material and the specific tool geometry. This paper presents a method for a tangential cutting force calculation along the given tool path based on processing of the high-frequency data acquired from the machine tool control system with support of the geometric material removal model. The calculated data are compared with the reference dynamometer results. The influence of the variable engagement parameters is demonstrated and discussed from the perspective of the in-process workpiece quality control. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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Direct laser interference patterning of cemented cutting tools 17

Direct laser interference patterning of cemented cutting too...

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Laser-based Micro- and Nanoprocessing XVII 2023

作者： Baumann, Robert Bouraoui, Yasmine Teicher, Uwe Selbmann, Erik Ihlenfeldt, Steffen Lasagni, Andrés Fabián Institute for Manufacturing Technology Technische Universität Dresden George-Baehr-Str. 3c Dresden01069 Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstraße 7a Dresden01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Fraunhofer Institute for Material and Beam Technology IWS Winterbergstraße 28 Dresden01277 Germany

ISBN: (纸本)9781510659230

Nowadays, improving processes sustainability has become a major topic for many manufacturers in metal processing industries. Next to the challenging rise of costs of raw material and tools, innovative and hard to process materials enter the market. Here, surface functionalization of cutting tools is devised as a convenient approach for reducing energy consumption as well as material losses. In this work, direct laser interference patterning (DLIP) is used for manufacturing periodic line-like structures with spatial periods of 5.5 µm on tungsten carbide. The texturing is applied on rake-flank faces of the cutting inserts, leading to texture depths up to 1.75 µm by controlling the amount of used laser pulses. Moreover, turning experiments under lubricated conditions carried out on Al 6061 T6 parts with structured and untreated tools are performed to investigate the tribological performance. In result, the used DLIP-functionalized cutting tools could effectively decrease machining forces up to 12 %. This is caused by the corresponding improvement in frictional and improved lubrication behavior at the tool/chip interface. Furthermore, the laser-processed tools generate thinner chips, which leads to a decrease in surface roughness by 31 % of the aluminum work piece. This work thus offers insight into the viability of improving cutting tools by laser surface micro patterning for upcoming innovative materials designed for improving tool wear resistance, energy efficiency and surface quality. © 2023 SPIE.

关键词： Tungsten carbide

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Electrochemical material removal characteristics of a NdFeB permanent magnet 22

Electrochemical material removal characteristics of a NdFeB ...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Petzold, Tom Martin, André Schubert, Andreas Chemnitz University of Technology Institute for Machine Tools and Production Processes Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9781998999118

Electric motors are used in various fields with an ever-increasing demand. In the electromobility sector as an example, a growth of a few hundred thousand motors per year is stated. In many cases, the rotor magnets for electric drives are produced by sintering. Special drives for two-axes positioning with precise movements require individual geometries of the rotor magnets such as spherical shapes. In this case, post-processing of the usually cylindrical or rectangular block shaped bar magnets is necessary. One common technique for post-processing is electrical discharge machining (EDM), which allows the machinability of hard or brittle materials, but also causes thermal impacts, which influence the magnetic properties of the material in a negative way. To overcome this negative effect it is necessary to re-magnetize the rotor magnets after EDM. Additional measurements of the magnetic field strength are required to ensure correct values. Electrochemical machining (ECM) represents an alternative technique for post-processing of rotor magnets, since it offers the possibility to avoid re-magnetization after the shaping process, because machining temperatures are well below the Curie temperature of most materials. In this study, ECM of a NdFeB permanent-magnetic material is presented. The experiments were carried out according to DIN-SPEC 91399. The material-specific removal characteristics indicate an active dissolution with the chosen machining parameters. Comparative measurements of the magnetic field strength before and after ECM indicate that there is no negative influence of the removal process. The results suggest that ECM with pulsed current and oscillating tool cathode is an applicable technique for shaping rotor magnets. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Neodymium alloys

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Subjective hearing sensation of process variations at a milling machine. How reliable will chatter marks be detected? 50

Subjective hearing sensation of process variations at a mill...

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50th International Congress and Exposition of Noise Control Engineering, INTER-NOISE 2021

作者： Trautmann, Florian Knöfel, Björn Drossel, Welf-Guntram Troge, Jan Freund, Markus Penter, Lars Anders, Damian Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Strasse 44 Dresden01087 Germany University of Technology Dresden Dresden01062 Germany

ISBN: (纸本)9781732598652

Intuition enables experienced machine operators to detect production errors and to identify their specific sources. A prominent example in machining are chatter marks caused by machining vibrations. The operators assessment, if the process runs stable or not, is not exclusively based on technical parameters such as rotation frequency, tool diameter, or the number of teeth. Because the human ear is a powerful feature extraction and classification device, this study investigates to what degree the hearing sensation influences the operators decision making. A steel machining process with a design of experiments (DOE)-based variation of process parameters was conducted on a milling machine. Microphone and acceleration sensors recorded machining vibrations and machine operators documented their hearing sensation via survey sheet. In order to obtain the optimal data set for calculating various psychoacoustic characteristics, a principle component analysis was conducted. The subsequent correlation analysis of all sensor data and the operator information suggest that psychoacoustic characteristics such as tonality and loudness are very good indicators of the process quality perceived by the operator. The results support the application of psychoacoustic technology for machine and process monitoring. © INTER-NOISE 2021 .All right reserved.

关键词： Audition

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Improvement of cutting tools using laser-induced periodic surface structures for machining Aluminium alloy Al 6061 T6 17

Improvement of cutting tools using laser-induced periodic su...

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Laser-based Micro- and Nanoprocessing XVII 2023

ISBN: (纸本)9781510659230

Improving processes sustainability to address upcoming demands in metal processing industries such as innovative and hard to process materials has become a major topic for many manufacturers. Therefore, new tool material compositions or surface coatings are continuously developed. In this context, surface functionalization of cutting tools is foreseen as a convenient approach for minimizing material losses and thus energy consumption. In this work, laser induced periodic surface structures (LIPSS) are used for manufacturing quasi-periodic line-like patterns on tungsten carbide inserts. The textured tool surfaces show low spatial frequency LIPSS (LSFL) with spatial periods of 500 nm to 600 nm as well as high spatial frequency LIPSS (HSFL) with a spatial period of ~100 nm. Furthermore, the texturing is applied on rake and flank faces of the cutting tools with different offsets to the edge between 0 and 0.2 mm. The wettability analysis reveals a decrease of static contact angles for the used cutting fluid (CIMSTAR) from 38° to 12°, suggesting an improved cooling process during the machining step. In addition, turning experiments under lubricated conditions are carried out on Al 6061 T6 parts to investigate the tribological performance. The used LIPSS-functionalized cutting tools could effectively decrease the main machining forces by 10 %, the feed force by 21 % and the passive force by 9 %. Furthermore, the laser-processed tools generate thinner chips, which leads to a decrease in surface roughness by 31 % of the aluminum work piece. © 2023 SPIE.

关键词： Turning

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Concentric jet for confined mask-less anodic dissolution and oxidation of aluminium 23

Concentric jet for confined mask-less anodic dissolution and...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Martin, André Quitzke, Susanne Morgenstern, Roy Schubert, Andreas Lampke, Thomas Chemnitz University of Technology Institute for Machine Tools and Production Processes Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Chemnitz University of Technology Institute of Materials Science and Engineering Materials and Surface Engineering Erfenschlager Str. 73 Chemnitz09125 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9781998999132

Anodic oxide layers are established for wear and corrosion protection of surfaces of aluminium parts and for decoration purposes. Usually, anodizing is carried out in large scale on the whole part surface or locally by masking through immersion in an electrolytic bath. Applying a free jet of electrolyte offers laterally confined anodizing without extensive efforts for masking and enables local functionalization without undesired influence on the surrounding surfaces in a resource- and energy-efficient process. However, the high ohmic resistance of anodic oxides leads to a wide distribution of the current density hindering laterally confined anodizing. More sharp-contoured anodic oxides are aspired through dilution of the electrolyte film flowing off laterally from the aluminium surface. For this purpose, a concentric arrangement of an electrolyte jet surrounded by a jet of deionized water was realized. Investigations on the distribution of electric current density were carried out by electrochemical machining experiments (Jet-ECM). The application of an actively anodic dissolving electrolyte of NaCl indicates the widening of the current density distribution in terms of pitting corrosion. Compared to the free electrolyte jet surrounded by atmospheric air, a wider current density distribution was detected when applying a concentric jet of deionized water. But the shape of the dissolved cavities was not widened, which indicates only low current density values on the surrounding surface. Verification experiments on anodization confirm the comparably strong localization of anodic oxides with concentric jet and an increase in thickness compared to the results with free electrolytic jet. It was found that this is mainly because of the high ohmic resistance of the anodic oxide formed on the surrounding surface and its increasing resistance at farther lateral distance from the jet due to stronger electrolyte dilution. © 2023 Euspen Headquarters.

关键词： Electrolytes

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Influence of clearance and velocity during blanking on the fatigue behavior of cellulose-based biocomposites

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Procedia CIRP 2024年 125卷 54-59页

作者： Ronja Scholz Sven Winter Alexander Delp Tobias Breitfeld Verena Psyk Welf-Guntram Drossel Frank Walther Chair of Materials Test Engineering (WPT) TU Dortmund University Baroper Str. 303 D-44227 Dortmund Germany Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Reichenhainer Strasse 88 D-09126 Chemnitz Germany Institute for Machine Tools and Production Processes (IWP) Chemnitz University of Technology Reichenhainer Strasse. 70 D-09126 Chemnitz Germany

Cellulose-based biocomposites, such as Cottonid, are a promising class of materials to improve the carbon footprint of products during their service life. Cottonid has high technological potential due to its physical and mechanical similarities to engineering plastics and light metals. To replace traditional metallic materials in industry, cellulose-based semi-finished products need to be formed and cut. In particular, blanking is the most cost-effective and industrially common cutting method for metals. However, this study investigates the influence of various blanking process parameters on the quality and the fatigue strength of the resulting cutting edges of Cottonid. The presented results give insights on how the relationships between process parameters during cutting and resulting material properties known from conventional materials can be transferred to cellulose-based biocomposites like Cottonid. The relative clearance was varied between 4 and 10% and the cutting velocity between 0.05 and 10 m/s. It was evident that slower velocities and smaller clearances resulted in visibly better cutting edges. In order to relate this effect to the mechanical performance of Cottonid, new 3-point bend specimens were taken from the blanked strips for fatigue testing. It was found that the fatigue strength was significantly affected by the velocity and clearance. Further, similar to metallic materials, clean-cut (smooth area) and a fractured zone can be clearly distinguished. A good cutting edge quality results in a higher resistance of the Cottonid component against crack initiation at process-induced defects. The knowledge gained may enable an efficient cutting process for cellulose-based materials with higher fatigue strength in the future.

关键词： Cottonid Cellulose Shear Cutting High-Speed Impact Cutting Fatigue Cutting Edge Quality

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Effects of abrasive waterjet cutting on surface properties of hardened steel

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Procedia CIRP 2023年 118卷 620-625页

作者： Nermin Redžić Philipp Kieweg Joachim Regel Martin Dix Chemnitz University of Technology Institute for Machine Tools and Production Processes Reichenhainer Str. 70 09126 Chemnitz Germany Franke GmbH Obere Bahnstraße 64 73431 Aalen Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

The importance of cutting hardened materials without influencing their structural properties makes abrasive waterjet machining a favorable choice in certain applications in comparison with other manufacturing technologies. Using this technology, faulty surface structures and errors caused by high thermal loads such as burrs, burns and cracks, can be avoided. In this paper, the results of applying the abrasive waterjet technology for cutting of hardened steel and its advantageous properties in comparison with cut-off grinding will be presented. The influence of process parameters on surface properties and burr formation has been determined by experimental analysis.

关键词： abrasive waterjet machining hardened steel cut-off grinding burr formation

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Investigation of bio-based cooling lubricants for the machining of aircraft stainless steels

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Procedia CIRP 2022年 110卷 47-52页

作者： Erik Selbmann Marcus Preiẞ Anas Ben Achour Uwe Teicher Albrecht Hänel Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU 01187 Dresden Germany Technische Universität Dresden Institute of Mechatronic Engineering 01062 Dresden Germany

Water-miscible cooling lubricants are used in approx. 90% of metalworking processes mainly for lubrication and cooling of the contact zone between tool and workpiece. The base oils of the widely used water-miscible emulsions are often of mineral origin and represent a significant share of the CO2-fingerprint in production systems in terms of their extraction, processing and the possibility of recycling. Cooling lubricants are furthermore negatively discussed regarding to their health compatibility. Those disadvantages of conventional cooling lubricants drive the research for replacing mineral base oils with vegetable base oils, which contribute to a safer work environment and greener production. In this work, both conventional cooling lubricants and several water-miscible emulsions with various edible and non-edible vegetable-based oils were prepared and characterized regarding their suitability as cooling lubricants for the milling of aircraft stainless steels. Comprehensive experimental investigations were carried out to determine the process forces and the resulting tool wear as technical performance indicators for the test evaluation.

关键词： Bio-based lubricants stainless steel milling process forces tool wear

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Identification and classification of color textures 30

Identification and classification of color textures

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30th International Conference on Computer Graphics and machine Vision, GraphiCon 2020

作者： Mende, Mattias Wiener, Thomas Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

This article describes, how color textures can be reliably detected and classified in the production process independent of external parameters such as brightness, object positions (translation), angulars (rotation), object distances (scaling) or curved surfaces (rotation + scaling). The methods described here are also suitable for reliably classifying at least 18 color textures even if they differ only slightly from each other optically. The online classification of color textures is a classic task in the wood, furniture and textile industry. For example, unwanted defects or partial soiling on moving webs can be reliably detected regardless of fluctuations in brightness and/or shadows during process operation. Algorithms has been developed for teach-in with RGB-HSI-transform, set fewer segments on the color textures of each class with e.g. 24x24 Pixel, use suitable transformations {HSI}, e.g. 2D-FFT for formation characteristic 2D spectral mountains in these segments, extraction of statistical features and setting up the individual classifiers. Algorithms has been developed for identification & classification in process operation with extraction of statistical characteristics and methods of robust classification. The implementation of the methods, the triggering of the color cameras, the processing of the color information including the output of the results to the process control is done with the data analysis program Xeidana®. © 2020 for this paper by its authors. Use permitted under Creative Commons License Attribution 4.0 International (CC BY 4.0).

关键词： Color

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