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14th International Conference on technology of Plasticity, ICTP 2023

作者： Psyk, Verena Linnemann, Maik Henkel, Marcel Kräusel, Verena Dix, Martin Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (纸本)9783031413407

Electromagnetic forming offers high potential for producing high-quality joints of similar and dissimilar materials. This can be exploited e. g. in aircraft design for assembly of struts. In order to give insight in the interactions between different influencing parameters and their effect on the loadability of the resulting joint in electromagnetic form-fit joining, design of experiments was used in a comprehensive study. Groove parameters (shape, depth, width and edge radius) and the capacitor charging energy were varied in joining experiments considering tubes made of EN AW-2024 (T351) with an outer diameter of 70 mm and, a wall thickness of 1.6 mm together with end parts made of the same material with a diameter of 66.8 mm. The loadability of the resulting compound was evaluated considering axial compression force. One important finding was that triangular grooves can provide highest loadability if relatively deep grooves, well-adjusted groove width and suitable capacitor charging energy are applied. An optimized groove edge radius can contribute to further improvement of the loadability. Numerical simulations on different groove shapes were performed in order to study the development of the forming stages during the process and to explain the trends observed in the experimental study. © 2024, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Aluminum

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Data preparation for AI-based robot control 16

Data preparation for AI-based robot control

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

作者： Abdolmohammadi, Tina Ahrens, Antje Richter-Trummer, Valentin Todtermuschke, Marcel Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 Chemnitz09126 Germany

Roll-profiling is traditionally used for low-cost, high-volume manufacturing. However, complex sheet metal parts usually require labor-intensive forming processes, including post-forming straightening processes, to achieve optimal tolerances, thus increasing cost. Robotic roll-profiling already paves the way for single-part manufacturing. The current work focuses on developing the foundations for AI-based control strategies for in-line straightening, eliminating the need for post-forming straightening processes. Reaction forces and torques on the forming tool were analyzed and compared to part geometry reference measurements. Data processing and evaluation were developed, and different regression algorithms and neural networks were compared. © 2023 Elsevier B.V.. All rights reserved.

关键词： Data handling

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Structure and Validation of a Kinematic Surface Simulation Model for the ultrashort-pulse Direct-Laser-Writing Process 20

Structure and Validation of a Kinematic Surface Simulation M...

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20th CIRP Conference on Modeling of Machining Operations in Mons, CIRP CMMO 2025

作者： Wieland, Fabian Gärtner, Eric Wieland, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Functional Surfaces and Micromanufacturing Reichenhainer Str. 88 Chemnitz09126 Germany

This paper presents the development and validation of a kinematic surface simulation model for the prediction of ultrashort-pulsed laser structured surfaces. The simulation is based on an existing kinematic simulation model for short-pulsed laser structuring and utilizes the stepwise Boolean intersection of a machined and digitized single point ablation with the workpiece to reproduce the microstructuring process. The existing short-pulse simulation model was extended by newly integrated description models to allow a more detailed representation of within the process changing influences, e.g. the surface fine-structure to enable a multi-layer processing. In addition, a reorganization of the simulation algorithm resulted in a general improvement of the run time and a resolution-independence. Based on the kinematic simulation principle, the manufacturing process for a wide range of material-machine combinations in the field of laser structuring can be described. The model enables a time-efficient, nanometer-resolved prediction of representative surfaces with a size of up to several square millimeters. Furthermore, complex influences such as material- and temperature-related properties do not need to be considered separately, as they are taken into account by the machined and digitized single point ablation. Compared to artificial intelligence approaches and numerical or multiphysical simulations, the need for preliminary studies is very low. Depending on the chosen laser machining parameters the simulation can reproduce the surface textures macro- and microstructure. © 2025 Elsevier B.V.. All rights reserved.

关键词： Kinematics

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Methods for the environmental and economic assessment in early product design - A case study-based overview for wind turbines in urban areas 31

Methods for the environmental and economic assessment in ear...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Zumpe, Martin Stange, Maximilian Burak Ertem, Ahmet Süße, Marian Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The assessment of environmental impacts has become an inevitable necessity for many manufacturing companies - not only from a mere retrospective viewpoint but also for product design decisions. At the same time, economic feasibility must be constantly considered throughout all product design phases. For both dimensions, many different decision-support methods exist. However, there is a lack of combined assessment methods especially in early product design phases, when product characteristics, manufacturing technologies and corresponding data are still uncertain. The paper provides an overview and qualitative evaluation of different methods for economic and ecological assessment in product design stages. Based on this, a generalized procedure for combined economic and ecological decision-making during product design is derived, highlighting possible coping mechanisms for uncertain or insufficient data. Both, the evaluation of available assessment methods as well as the derived procedure are transferred to the specific requirements of wind turbines in urban areas. As a result, open research aspects and the next steps for method development are derived. © 2024 The Author(s).

关键词： Product design

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Combining material flow simulation and optimization for sustainable manufacturing - Application in automotive paint shops 31

Combining material flow simulation and optimization for sust...

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31st CIRP Conference on Life Cycle Engineering, LCE 2024

作者： Süße, Marian Xie, Xinyi Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The necessity for sophisticated decision support in industrial manufacturing has been described manifoldly and simulation approaches as well as optimization methods are continuously developed. This can be especially promising when it comes to decision-making with multidimensional requirements of economic and ecological efficiency. However, due to the required expert knowledge, there is still a gap between theoretically applicable and industrially applied methods. The paper therefore presents results of two use cases as part of the European project ECOFACT where different approaches for the combination of simulation and (heuristic) optimization were applied with industry partners. An overview of recent works and systematic literature reviews of sustainable manufacturing and the approaches for combining simulation and optimization is given. Correspondingly, the investigated use cases of automobile paint shops refer to the reduction of environmental impacts by optimized heating processes and an improved batching process to minimize paint waste. In the first case, setup times for heating color pools and ovens were shifted to avoid load peaks in a calculation time of less than one minute. In the second use case batch size was increased by around 25%. © 2024 Elsevier B.V.. All rights reserved.

关键词： Paint

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Modeling of tool load for optimization of tool life in diagonal generating grinding 19

Modeling of tool load for optimization of tool life in diago...

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19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Rößler, Maximilian Krage, Robin Dix, Martin Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Diagonal continuous generating grinding with ceramic bonded wheels is commonly used for hard finishing of automotive gears with topological modifications. In this process, areas of the grinding wheel have to be used repeatedly to machine multiple components, resulting in not achieving the same tool life as conventional generating grinding. This paper presents a detailed process model predicting loads on the wheel as a basis for an optimization of tool life. Based on a redistribution of the roughing and shifting areas of the grinding wheel, significantly lower wear could be demonstrated in tests. © 2023 Elsevier B.V.. All rights reserved.

关键词： Grinding (machining)

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A novel model-based approach for the design of scalable crimp connectors for SMA wire-based actuators

A novel model-based approach for the design of scalable crim...

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

作者： John, Benjamin Kübler-Tesch, Johannes Pagel, Kenny Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology Saxony Dresden Germany

ISBN: (纸本)9781627084840

While SMA wire-based actuators hold great potential across a range of industries, including medical, automotive, and consumer goods, the system integration of these wires poses a significant challenge, particularly in the context of fully automated mass production. Currently in all known industrial applications, only crimp or splice connectors are employed to connect the wire to its system environment. However, there is no standardized method for systematically designing crimp connectors while considering application-specific requirements. Furthermore, the property rights situation becomes more restrictive, as the protection claim of an expanding number of patents extends beyond the technical design of SMA actuators to their production processes in detail. Nevertheless, crucial process characteristics, particular those related to a crimping process, are undisclosed. In addition, since these documents usually describe specific products, transferring them to other applications remains difficult. To address these challenges, the fundamental connection mechanisms of crimp connectors will be analyzed, and an easily scalable crimping concept will be developed, considering existing intellectual property rights. This crimping concept is then characterized by a parameter study using the Design of Experiments method and static pull-out tests to identify crucial influencing factors and their interactions and to be able to build a mathematical model that maps the parameter- dependent pull-out strength of the connection. Based on the theoretical analysis of the fundamental connection mechanisms and the practical insights into influences and interactions affecting the static pull-out strength of the crimp connection, a systematic method will be devised to facilitate the design of model-based, cycle-resistant crimp connections in accordance with application-specific requirements. © 2024 ASM International® All rights reserved.

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A survey on smart product-service systems in manufacturing 56

A survey on smart product-service systems in manufacturing

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56th CIRP International Conference on Manufacturing Systems, CIRP CMS 2023

作者： Mauersberger, Anton Alaluss, Mohaned Beyer, Antonia Nölscher, Kilian Armin Rauscher, Alexander Reinhardt, Heiner Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The advancing digitization affects product design and manufacturing. Companies focus on product-service systems (PSS) to improve customer satisfaction and loyalty. However, these PSS become increasingly complex as digital technologies are incorporated and cross-company collaboration and manufacturing is facilitated. In essence, we can observe a transition from conventional PSS to smart PSS, where the opportunities of digitization are effectively utilized and synergies between multiple stakeholders are fostered. Here, we present an analysis and classification of smart PSS considering aspects of business modeling, composition, design, quality and sustainability. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://***/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the 56th CIRP International Conference on Manufacturing Systems 2023.

关键词： Decision making Development Innovation management Modular design Product-service system Production Remote service Smart PSS Smart service Smart technologies

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Simulation tool for chatter prediction of varying tool-machine configurations based on dynamic substructuring 19

Simulation tool for chatter prediction of varying tool-machi...

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19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Schuster, Alexander Sahu, Govind N. Rentzsch, Hendrik Otto, Andreas Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

Cutting tools of different type, shape and size are used in milling processes. Every individual tool changes the dynamic behavior of the system and results in varying occurrences of chatter vibrations. This paper presents a simulation tool using a frequency based substructuring method for predicting the process stability without separate measurements of the tool-machine configuration. In particular, frequency response functions of any combined tool-machine configuration is synthesized by the receptance coupling substructure analysis. It enables the calculation of critical machining parameters and maximizing material removal rates by avoiding unstable cutting conditions. Verification is done via finite element analysis of exemplary tool and machine structures. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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Process concatenation to reduce thermal changes in machine tools

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International Journal of Mechatronics and Manufacturing Systems 2022年第2-3期15卷 167-184页

作者： Wenkler, E. Selch, M. Hellmich, A. Ihlenfeldt, S. Institute for Machine Tools and Control Engineering Technische Universität Dresden Dresden01062 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden01069 Germany

Thermal effects in machine tools are responsible for a significant amount of produced scrap. Therefore, various approaches have been investigated and applied on machine tools to reduce thermal changes during manufacturing. Most of them target the machine tool and its operational state and can therefore just react to the thermal changes caused by the process. This paper shows how thermal changes can be reduced already in the manufacturing planning stage. With the use of a virtual numerical control (VNC) and loss models, power losses can be estimated, enabling the concatenation of processes to achieve minimal jumps in power loss from one process to another. Copyright © Inderscience Enterprises Ltd.

关键词： Energy efficiency

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