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Methodology for the design of recursively axially formed rotor shafts made of two or more combined segments

Procedia Manufacturing 2019年 27卷 13-20页

作者： R. Kurth R. Tehel T. Päßler H. Wagner D. Beihofer Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Felss Systems GmbH Dieselstraße 2 75203 Königsbach-Stein Germany

Electric drives are used in all industrial fields in a growing number. Whereas the rotor shafts used in the area of machinery and plant engineering are designed as solids, the shafts mainly used in the field of automotive industry are hollow shafts focusing on the lightweight potential and the improvement of motor characteristics. This paper describes a shaft design consisting of two or more segments manufactured by a new combination of certain cold forming processes before joining. This design enables higher flexibility of variants as well as optimization of production efficiency and logistic chains. Thus, the joint zone design is a special serration with a helix angle in order to reach a high robustness of the shaft. A detailed FEM simulation of the elastoplastic behavior of the joint zone and the mechanical characteristics of the complete shaft leads to an evaluation of possible applications of this joint geometry and the corresponding manufacturing process. Based on experimental investigations, the simulations have been validated successfully. An empirical model designed by regression analysis of further simulation results is used to propose a design methodology for the identification of design parameters of the assembled shaft and the joint zone as well. These parameters can be used for planning the forming processes and the blank geometry.

关键词： forming rotor shaft finite element method (FEM) axial forming rotary swaging joining serration

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Combined and fast computable thermal models for situationally optimal tempering of machine tool components

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Procedia CIRP 2019年 79卷 608-613页

作者： Juliane Weber Janine Glänzel Jens Popken Linart Shabi Jürgen Weber Institute of Fluid Power TU Dresden Helmholtzstr. 7a 01069 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

The focus of this paper is on the modeling of an existing machine frame with its cooling structures. An overview is given of all the modeling methods used, their respective sub-targets and their interactions with each other. The modeling workflow encompasses both the mechanical and fluidic properties of the machine frame, including the fluid circuits and their control. The study results are the different requirements for modeling and the achievable result accuracy with regard to the temperature and deformation field. It forms the basis for the subsequent investigation of various temperature control variants, which are not part of this paper.

关键词： machine tools machine frame Cooling system Modeling CFD FEM Network-based 1D modeling

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“Evaluation of a method to measure the friction coefficient between vital mandibular bone and biomedical materials”

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Biotribology 2021年 28卷

作者： Ben Achour, Anas Petto, Carola Meißner, Heike Mostofa, Anita Teicher, Uwe Ihlenfeldt, Steffen Lauer, Günter Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden 01187 Germany Department of Oral and Maxillofacial Surgery University Hospital Carl Gustav Carus Dresden Technische Universität Dresden Fetscherstraße 74 Dresden 01307 Germany Department of Prosthetic Dentistry University Hospital Carl Gustav Carus Dresden Technische Universität Dresden Fetscherstraße 74 Dresden 01307 Germany

Purpose: The aim of this study is to evaluate a developed experimental set-up to measure the coefficient of friction between fresh mandibular bone and biomaterials used in oral and maxillofacial surgery including a standardized routine for specimen preparation. Material and methods: For this purpose, we developed a specialized routine for harvesting and preparation of cortical bone specimen from cadaveric porcine mandibles and modified a ball-plate tribometer. These harvested bone specimen were kept moist all the time. A total of 24 bone cylinders with 8 repetitions per material were examined for their coefficient of friction against stainless steel (1.4404), a titanium alloy (Ti6Al4V) and a cobalt‑chromium‑molybdenum alloy (Biosil F®) and subsequently analyzed by laser-scanning and scanning electron microscopy. Results: The lowest coefficients of friction between vital cortical bone and the investigated implant materials were found for Biosil F®, while the highest coefficients of friction were found for the titanium alloy Ti6Al4V. Significant differences for the initial coefficient of friction with p < 0.05 have been proven. Stick-slip effects occurred during the measurement and a layer of debris formed on the metallic samples. EDX analysis of the abrasion marks revealed that this layer consisted of elements contained in hydroxyapatites and carbon. Conclusion: The experimental set-up is suitable to perform reproducible comparative measurements of the coefficient of friction of different material combinations. A significant advantage of the methodology is the flexibility and scalability of harvesting and preparation of the bone specimen, which allows the simulation of realistic situations while measuring the coefficient of friction. © 2021 Elsevier Ltd

关键词： Biotribology Bone Experimental Friction coefficient Implant materials Tribology

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Correction to: Properties of a superelastic NiTi shape memory alloy using laser powder bed fusion and adaptive scanning strategies

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Progress in Additive Manufacturing 2021年第1期7卷 139-139页

作者： Gustmann, Tobias Gutmann, Florian Wenz, Franziska Koch, Peter Stelzer, Ralph Drossel, Welf‑Guntram Korn, Hannes Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Fraunhofer Institute for High-Speed Dynamics (Ernst-Mach-Institut) EMI Freiburg Germany Fraunhofer Institute for Mechanics of Materials IWM Freiburg Germany Chair of Engineering Design and CAD Technical University Dresden Dresden Germany

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Adapted scan strategy and slicing tool for improvement of strut precision in lattice structures

Adapted scan strategy and slicing tool for improvement of st...

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2018 ASPE and euspen Summer Topical Meeting on Advancing Precision in Additive Manufacturing

作者： Korn, Hannes Koch, Peter Kordaß, Richard Holtzhausen, Stefan Schöne, Christine Müller, Bernhard Stelzer, Ralph Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz / Dresden Saxony Germany Institute of Machine Elements and Machine Design Technische Universität Dresden Dresden Saxony Germany

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THE BIOMECHANICAL STABILITY OF A NOVEL BIOABSORBABLE MAGNESIUM ALLOY (ZX00:Mg–Zn–Ca) BONE ANCHOR FOR ROTATOR CUFF REPAIRS: A HUMAN EX VIVO STUDY

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Journal of Musculoskeletal Research 2025年第1期28卷

作者： Kinsky, Rudolf Maximilian Schleifenbaum, Stefan Honea, Maxim Siegert, Paul Hammer, Niels Fischerauer, Stefan Franz Weinberg, Annelie Wurnig, Christian Sanatorium Hera Loeblichgasse 14 Vienna 1090 Austria Department of Orthopedic Trauma and Plastic Surgery Semmelweisstraße 14 Raum-1322 (Sockelgeschoss) Leipzig D-04103 Germany Institute of Materials Science Joining and Forming Technical University of Graz Rechbauerstraße 12 Graz 8010 Austria Orthopaedic Hospital Speising 109 Speisingerstrasse Vienna 1130 Austria Division of Macroscopic and Clinical Anatomy Gottfried Schatz Research Center Medical University of Graz Auenbruggerplatz 25 Graz 8036 Austria Fraunhofer Institute for Machine Tools and Forming Technology Nöthnitzer Str. 44 Dresden 01187 Germany Department of Orthopaedic Trauma and Plastic Surgery University Clinics of Leipzig Liebigstr. 27 Leipzig 04109 Germany University Clinic f. Orthopaedics und Traumatology Medical University Graz Auenbruggerplatz 5 Graz 8036 Austria Musculo-Skeletal Research Unit for Biomaterials Department of Orthopaedics Trauma Medical University of Graz Auenbruggerplatz 5 Graz 8036 Austria

Introduction: The purpose of this study was to ascertain the primary ex vivo biomechanical stability of a novel bioabsorbable magnesium alloy (ZX00: Mg–Zn–Ca) bone anchor in human cadaveric proximal humeri, indicated in the reconstruction of the rotator cuff. Methods: Twenty human Thiel-embalmed cadaveric humeri were prepared and freed from soft tissue. One ∅5.7 × 20.5-mm ZX00 anchor and one ∅5.5 mm × 16.3 mm Arthrex Titanium FT Corkscrew (ATC) control anchor were inserted into the footprint of the supraspinatus tendon, 15 mm apart. The humeri were mounted onto a material testing machine and following a 40 N preload, cyclic loading was performed over 400 cycles. If the construct remained intact, ultimate load to failure (ULTF) was measured using an increasing axial load of 1 mm/s, ULTF and mode of failure were recorded. Results: No difference was found in the ability to withstand cyclic loading, mode or load-to-failure strengths between ZX00 and control anchors. The maximum tractional force loaded for the ZX00 anchors had a median of 257.4 N (range 165.3–328.2). The corresponding value for the ATC anchors averaged 239.9 N (range 118.9–306.7). Conclusion: ZX00 alloy anchors appear to provide adequate initial biomechanical stability when compared to an industry-standard control in a cadaveric rotator cuff repair model. © 2025 The Author(s)

关键词： Absorbable implants Alloys Magnesium Rotator cuff tear Arthropathy Shoulder injuries

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Structural health monitoring for fibre reinforced composites produced by the winding process 22

Structural health monitoring for fibre reinforced composites...

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22nd International Conference on Composite Materials, ICCM 2019

作者： Naumann, Mario D. Körner, Enrico Heinrich, Michael Kroll, Lothar Department of Lightweight Structures and Polymer Technology Technical University of Chemnitz Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Volkswagen AG Federal Cluster of Excellence MERGE Technical University of Chemnitz Chemnitz Germany Fraunhofer Project Center for Advanced Lightweight Technologies Opole Poland

In recent years, the power density as a ratio of internal pressure to mass of pressure vessels has steadily increased, which is particularly advantageous for the transportation of gases as fuel in vehicles. At the same time, high safety requirements combined with a high degree of lightweight construction usually correlate with an increased demand for cost-intensive high-performance materials. Also with the increasing introduction of hydrogen-powered vehicles, high safety measures play a central role for pressure vessels, which are usually serially manufactured. In order to provide progressive series solutions for this, new safety systems are moving into the focus of scientific efforts. Within the scope of intensive research work, the complete integration of a metallic sensor wire for the deformation measurement of a fibre-plastic composite pressure vessel as well as its functional verification is therefore being investigated. The structural integration of the sensor wire is based on a direct method, the so-called winding process. In the winding process, the reinforcing fibres are applied to a positive core. This results in closed moulded bodies in fiber reinforced plastic (FRP) design such as pipes, tanks, axles, pressure vessels and shafts. With the aid of a winding machine, a core (mandrel), which forms the shape of the component, is set in rotation and the reinforcing fibre is pulled off a creel with a defined yarn tension. At the same time, the sensor wire is fed through the same thread eye. The sensor wire thus follows the reinforcing fibre. This results in an exact positioning of the sensor wire along the reinforcing fibers and allows the measurement according to the stress of the composite structure. For the impregnation of the reinforcement fibres with the resin system, these are passed through a resin bath and then wound onto the mandrel. Furthermore, the impregnation of the sensor wires is carried out indirectly via contact of the sensor wires with the imp

关键词： Fiber reinforced plastics

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A novel hybrid clamping system for sheet metals and thin walled structures

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Procedia Manufacturing 2019年 40卷 51-55页

作者： Uwe Teicher Sebastian Pirl Andreas Nestler Arvid Hellmich Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden 01187 Germany Technische Universität Dresden Institute of Manufacturing Technology Dresden 01062 Germany Technische Universität Dresden Institute of Mechatronic Engineering Dresden 01062 Germany

Thin sheets and thin-walled structures are of great economic importance in the aerospace industry due to the enormous efforts being made in lightweight construction. The challenge in machining is to use a reliable clamping device to take account of the sheet metal or component structure as well as to work productively and reliably. For this purpose, a hybrid clamping system has been developed that functions on the basis of vacuum and the adhesive properties of a carrier medium in order to form a complex joining. This method was verified by material tests and then developed to make it usable for the HSC and HPC milling of aluminum sheets. For this purpose, demonstrator parts were manufactured in order to test the critical loads of this clamping system on the one hand and to produce structures that cannot be realized economically with other machining methods on the other hand.

关键词： clamping fixture machining sheet metal aluminum

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Basic material and technology investigations for material bonded hybrids by continuous hybrid profile fabrication

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IOP Conference Series: Materials Science and Engineering 2021年第1期1140卷

作者： K Schubert M Gedan-Smolka A Marschner T Rietzschel K Uhlig D Löpitz D Wagner M Knobloch Leibniz-Institut für Polymerforschung Dresden e.V. (IPF) Hohe Straße 6 01069 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Reichenhainer Straße 88 09126 Chemnitz Germany

The development of multi-material hybrids by injection molding has been studied very intensively at the IPF in the past. For that, a material bonding between the different substrates was achieved by using a newly developed two-step curing powder coating material as latent reactive adhesive. The aim of the project 'Hybrid Pultrusion' was to perform a novel approach for the fabrication of material bonded metal-plastic joints (profiles) in a modified pultrusion process. Therefore, powder pre-coated steel coil is combined with a glass-fiber reinforced epoxy resin matrix. For initial basic studies, the impregnated fiber material has been applied on the pre-coated steel sheets using the Resin Transfer Molding process (RTM-process). It was proved via lap shear tests, that this procedure resulted in very high adhesive strengths up to 35 MPa resulting from the formation of a covalent matrix-steel bonding as well. In addition, the failure mechanism was subsequently studied. Furthermore, by adapting the successful material combination to the pultrusion process it was demonstrated that material bonded hybrids can be achieved even under these continuous processing conditions.

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Process-oriented Flow Curve Determination at Mechanical Joining

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Procedia Manufacturing 2020年 47卷 368-374页

作者： Mathias Jäckel Sam Coppieters Nelis Vandermeiren Christian Kraus Welf-Guntram Drossel Noa Miyake Toshihiko Kuwabara Klaus Unruh Heinrich Traphöner A. Erman Tekkaya Tudor Balan Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden 01187 Germany KU Leuven Technology Campus Ghent Department of Materials Engineering Gebroeders De Smetstraat 1 Ghent 9000 Belgium Belgium Welding Institute Technologiepark 48 Ghent 9052 Belgium Institute of Engineering Tokyo University of Agriculture and Technology 3 Chome-8-1 Harumicho Tokyo 183-8538 Japan Faurecia Autositze GmbH Nordsehler Straße 38 Stadthagen 31655 Germany Institute of Forming Technology and Lightweight Components TU Dortmund Baroper Straße 303 Dortmund 44227 Germany Arts et Metiers Institute of Technology Université de Lorraine LCFC HESAM Université F-57070 Metz France

The accuracy of numerical simulation models for forming processes depends highly on the method for the flow curve determination. Numerous experimental tests exist to identify the flow curves of sheet metals, each with certain characteristics regarding stress states and achievable strains. In this paper stress state analysis are presented for the mechanical joining techniques clinching as well as self-pierce riveting with semi-tubular rivet (SPR). Based on these findings flow curves for DC04 material are determined by selected experimental materials tests in order to compare the influence of the flow curve determination method on the accuracy of the process simulation models.

关键词： Mechanical Joining Material Chracterization Numerical Simulation

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