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IEEE International Conference on Robotics and Automation

作者： Mohamad Bdiwi Aquib Rashid Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (纸本)9781467380270

This research work proposes a robotized workstation for automatic disassembly of electric vehicle motors. A novel image processing algorithm is proposed for autonomous detection of motor screws, to automate the task of motor disassembly. Instead of having a database of templates for matching, the screws are detected based on their characteristics with respect to its grayscale, depth and HSV values. Furthermore, with frame iterations, the accuracy of the system is increased mean while reducing its runtime. The algorithm is successfully tested and implemented and yields highly accurate results.

关键词： Disassembly Electric Vehicle

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3D analysis in laser beam melting based on real-time process monitoring

3D analysis in laser beam melting based on real-time process...

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Materials Science and technology Conference and Exhibition 2016, MS and T 2016

作者： Toeppel, Thomas Schumann, Philipp Ebert, Marie-Christin Bokkes, Tobias Funke, Kerstin Werner, Michael Zeulner, Fabian Bechmann, Florian Herzog, Frank Fraunhofer Institute for Machine Tools and Forming Technology IWU Noethnitzer Str. 44 Dresden01187 Germany Concept Laser GmbH An der Zeil 8 Lichtenfels96215 Germany

ISBN: (纸本)9781510833142

In the course of increasing application of laser beam melting (LBM) technology for series production, LBM process monitoring becomes more and more important for quality control during and after the production process. Especially for safety-relevant parts, such as aircraft and motorsport components or medical implants, process robustness and quality assurance is basic assumption for a wide adoption of LBM technology in these industries. Furthermore, real-time monitoring is fundamental for self-regulating process control of LBM machines. But before that, extensive research on interrelations between sensor signals and process conditions need to be done. In this contribution, newest results on process failure and defect detection using Concept Laser's coaxial IR camera and photodiode based QM Meltpool 3D are addressed. This systems newest 3D feature, providing a detailed 3D landscape of position-related meltpool characteristics, is compared to CT inspection data. Hence, advantages for part inspection and it's usage in research are presented. Copyright © 2016 MS&T16®.

关键词： Process monitoring

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Investigation of Turning Elastomers Assisted with Cryogenic Cooling

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Procedia CIRP 2016年 40卷 631-636页

作者： M. Putz M. Dix M. Neubert G. Schmidt R. Wertheim Technische Universität Chemnitz Institute for Machine Tools and Production Processes (IWP) Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Germany

Elastomer components are normally produced by a molding process. When it comes to small batch sizes this becomes inefficient due to the expensive production of the molding tool, and machining is an economic alternative. However, due to the very low Young's modulus elastomers are difficult to machine. The investigated approach to enhance machinability was to use cryogenic cooling during cutting elastomer components, changing their mechanical properties. Experiments in turning show that elastomers do not respond like ordinary metal materials. Hence this study is conducted to describe the effects occurring during turning elastomers assisted with cryogenic cooling. Therefore extensive tests were carried out to determine the material characteristics. Forces and tool temperatures were measured in turning tests. A rise in tangential cutting force by approximately 30% compared to dry machining verifies the change in material properties at very low temperatures. This correlates with the measured tensile strength at different temperatures. The examined surface integrity and the formed chips confirm the improvement in machinability under cryogenic conditions as a result of lower material deformation. In addition the friction between tool and chip was evaluated by applying a temperature dependent friction law.

关键词： Cutting Cryogenic machining hard-to-cut materials

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Influence of Microstructures on Tribological Systems - Development of Process and Surface Structure

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Procedia CIRP 2016年 46卷 281-284页

作者： Gerhard Regel Matthias Putz Peter Blau Carsten Hochmuth Uwe Frieß Maik Fiedler Fraunhofer Institute for Machine Tools and Forming Technologie IWU 09126 Chemnitz Germany

Requirements are constantly rising for friction and wear reduction of moved components in combustion engines. Numerical simulations and investigations have demonstrated the potential of microstructured surfaces at tribological highly stressed sliding contacts, in particular the cam- tappet contact area. Using the innovative cutting process of single-grain scratching, the microstructures shall be implemented. The requirements of this implementation are defined based on simulations for cam-tappet contacts. After determining boundary conditions an empirical process model for the scratching process is created. It forms the basis for fundamental investigations carried out on the technology development. By conducting subsequent experimental investigations, relationships between the influencing parameters are established. Finally the process model and the results of the experiments lead to a device for integrating this process into existing production chains.

关键词： Friction Tribology Wear Process development Abrasive grain Microstructure

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Surface structuring of boron doped CVD diamond by micro electrical discharge machining

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AIP Conference Proceedings 2018年第1期1960卷

作者： A. Schubert T. Berger A. Martin M. Hackert-Oschätzchen N. Treffkorn R. Kühn 1Professorship Micromanufacturing Technology Faculty of Mechanical Engineering Chemnitz University of Technology 09107 Chemnitz Germany 2Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

Boron doped diamond materials, which are generated by Chemical Vapor Deposition (CVD), offer a great potential for the application on highly stressed tools, e. g. in cutting or forming processes. As a result of the CVD process rough surfaces arise, which require a finishing treatment in particular for the application in forming tools. Cutting techniques such as milling and grinding are hardly applicable for the finish machining because of the high strength of diamond. Due to its process principle of ablating material by melting and evaporating, Electrical Discharge Machining (EDM) is independent of hardness, brittleness or toughness of the workpiece material. EDM is a suitable technology for machining and structuring CVD diamond, since boron doped CVD diamond is electrically *** this study the ablation characteristics of boron doped CVD diamond by micro electrical discharge machining are investigated. Experiments were carried out to investigate the influence of different process parameters on the machining result. The impact of tool-polarity, voltage and discharge energy on the resulting erosion geometry and the tool wear was analyzed. A variation in path overlapping during the erosion of planar areas leads to different microstructures. The results show that micro EDM is a suitable technology for finishing of boron doped CVD diamond.

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Manufacturing of Long Products Made of Innovative Lightweight Materials

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Acta Metallurgica Sinica(English Letters) 2015年第12期28卷 1496-1502页

作者： Karsten Richter Roland Müller Andreas Kunke Verena Kr? usel Dirk Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Professorship Forming and Joining (UFF) Technische Universit?t Chemnitz

The processing of innovative lightweight materials to sheet metal components and assemblies with globally or locally defined properties is the object of this work. It takes a load-dependent design of components and assemblies, for example, based on the composition of different construction materials or a targeted setting of component areas with specified characteristics to fully exploit the lightweight potential when substituting conventionally used materials. Different process chains for the manufacturing of roll-formed long products made of magnesium alloys and high-strength steels with locally defined properties will be presented in this paper. Depending on the kind of material to be formed and the desired product characteristics, different temperature managements are needed for capable processes. Due to limited formability at room temperature, magnesium alloys require a heating of the forming zones above 200–225 °C throughout the bending process in order to activate additional gliding planes and to avoid any failures in the radii. The realization of local hardening effects requires at least one process-integrated heat treatment when roll forming manganese–boron steels. For both processes, it is imperative to realize a heating and cooling down or quenching appropriate for the manufacturing of long products with the required quality. Additionally, proper line speeds that allow a continuously operated economical production have to be considered. Research results including design, FEA, realization and experimentation of the mentioned process chains and strategies will be described in detail.

关键词： Roll forming Heat treatment Lightweight component Light metals Manganese steels AZ31 magnesium alloy

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Adaptronic Applications in Cutting machines

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Procedia CIRP 2016年 46卷 303-306页

作者： W.-G. Drossel A. Bucht K. Pagel T. Mäder T. Junker Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Adaptronic systems are able to improve high performance cutting technologies making them more stable, economic and efficient leading to a higher product quality. The main objectives of adaptronic systems in production technologies, beyond controlling process parameters, are either reducing vibration or generating them. The latter topic is a highly innovative area of research since it offers alternative approaches to improve product quality and optimize machining processes regarding efficiency and economy. Current research at fraunhofer institute for machine tools and forming technology iwu focuses on facilitating the transfer of scientific knowledge to industrial solutions. Therefore, possible reasons preventing industrial application of adaptronic systems in cutting machines are identified and initial ideas to overcome these problems are presented.

关键词： machine tool Adaptive control Vibration assisted machining

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Manufacturing of hybrid aluminum copper joints by electromagnetic pulse welding – Identification of quantitative process windows

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AIP Conference Proceedings 2017年第1期1896卷

作者： Verena Psyk Christian Scheffler Maik Linnemann Dirk Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology – IWU Reichenhainer Strasse 88 09126 Chemnitz Germany

Compared to conventional joining techniques, electromagnetic pulse welding offers important advantages especially when it comes to dissimilar material connections as e.g. copper aluminum welds. However, due to missing guidelines and tools for process design, the process has not been widely implemented in industrial production, yet. In order to contribute to overcoming this obstacle, a combined numerical and experimental process analysis for electromagnetic pulse welding of Cu-DHP and EN AW-1050 was carried out and the results were consolidated in a quantitative collision parameter based process window.

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Process development and tooling design for intrinsic hybrid composites

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Journal of Physics: Conference Series 2017年第1期896卷

作者： M Riemer R Müller W G Drossel D Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz www.iwu.fraunhofer.de

Hybrid parts, which combine the advantages of different material classes, are moving into the focus of lightweight applications. This development is amplified by their high potential for usage in the field of crash relevant structures. By the current state of the art, hybrid parts are mainly made in separate, subsequent forming and joining processes. By using the concept of an intrinsic hybrid, the shaping of the part and the joining of the different materials are performed in a single process step for shortening the overall processing time and thereby the manufacturing costs. The investigated hybrid part is made from continuous fibre reinforced plastic (FRP), in which a metallic reinforcement structure is integrated. The connection between these layered components is realized by a combination of adhesive bonding and a geometrical form fit. The form fit elements are intrinsically generated during the forming process. This contribution regards the development of the forming process and the design of the forming tool for the single step production of a hybrid part. To this end a forming tool, which combines the thermo-forming and the metal forming process, is developed. The main challenge by designing the tool is the temperature management of the tool elements for the variothermal forming process. The process parameters are determined in basic tests and finite element (FE) simulation studies. On the basis of these investigations a control concept for the steering of the motion axes and the tool temperature is developed. forming tests are carried out with the developed tool and the manufactured parts are analysed by computer assisted tomography (CT) scans.

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Process simulation and experimental validation of Hot Metal Gas forming with new press hardening steels

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Journal of Physics: Conference Series 2017年第1期896卷

作者： A. Paul F. Reuther S. Neumann A. Albert D. Landgrebe Fraunhofer Institute for Machine Tools and Forming Technology (Fraunhofer IWU) Reichenhainer Straße 88 09126 Chemnitz Germany

One field in the work of the fraunhofer institute for machine tools and forming technology iwu in Chemnitz is industry applied research in Hot Metal Gas forming, combined with press hardening in one process step. In this paper the results of investigations on new press hardening steels from SSAB AB (Docol®1800 Bor and Docol®2000 Bor) are presented. Hot tensile tests recorded by the project partner (University of West Bohemia, Faculty of Mechanical Engineering) were used to create a material model for thermo-mechanical forming simulations. For this purpose the provided raw data were converted into flow curve approximations of the real stress-real strain-curves for both materials and afterwards integrated in a LS-DYNA simulation model of Hot Metal Gas forming with all relevant boundary conditions and sub-stages. Preliminary experimental tests were carried out using a tool at room temperature to permit evaluation of the forming behaviour of Docol 1800 Bor and Docol 2000 Bor tubes as well as validation of the simulation model. Using this demonstrator geometry (outer diameter 57 mm, tube length 300 mm, wall thickness 1.5 mm), the intention was to perform a series of tests with different furnace temperatures (from 870 °C to 1035 °C), maximum internal pressures (up to 67 MPa) and pressure build-up rates (up to 40 MPa/s) to evaluate the formability of Docol 1800 Bor and Docol 2000 Bor. Selected demonstrator parts produced in that way were subsequently analysed by wall thickness and hardness measurements. The tests were carried out using the completely modernized Dunkes/AP&T HS3-1500 hydroforming press at the fraunhofer iwu. In summary, creating a consistent simulation model with all relevant sub-stages was successfully established in LS-DYNA. The computation results show a high correlation with the experimental data regarding the thinning behaviour. The Hot Metal Gas forming of the demonstrator geometry was successfully established as well. Different hardness values could b

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