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Europe-Asia Congress on Mechatronics

作者： Thorsten P. Klein Benny Drescher Gunther Reinhart Project Group Resource-efficient Mechatronic Processing Machines (RMV) Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Beim Glaspalast 5 86153 Augsburg Thorsten Project Group Resource-efficient Mechatronic Processing Machines (RMV) Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Beim Glaspalast 5 86153 Augsburg

ISBN: (纸本)9781509017881

Agile procedures (e.g. Scrum) are applied in software engineering increasingly. These procedures enhance interdisciplinary collaboration, improvements of lead times and reduction of development costs. Hence, latest research activities are transferring such flexible techniques into machinery and plant construction, in order to cope with the rising software integration into mechatronic modules. As agile procedures have been omitted in mechanical engineering yet, we introduce a novel concept of a learning platform about Agile Engineering. This paper presents the background and experiences of Agile Engineering as well as the setting, the results and first educational achievements within our academic courses.

关键词： Agility Scrum Mechatronics Lean Product Development Development Process Learning Platform

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Faster temperature control systems for hot embossing and injection molding 15

Faster temperature control systems for hot embossing and inj...

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15th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2015

作者： Edelmann, Jan Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (纸本)9780956679079

Research work aims to develop a fast, production suitable hot embossing technology including appropriate tool systems for low-cost and production-integrated manufacturing of high-precision microfluidic structures in polymer films. The implementation is demonstrated by structuring of microfluidic films for disposable diagnostic devices used in home-care and point-of-care applications. The approach focuses on the development and thermal design of a tool system for fast hot embossing on basis of a fast non isothermal process. Close contour tempering of the active parts is the core of this approach. Based on an industrial specification the paper will describe tempering strategy, design and simulation of the tool concept. Heat flux and heat capacities together with the power loss in the system are used for calculating the tempering cycle. Based on that, the setup of an optimized tool system consisting of heating elements and a refrigerant system is presented. The new tool concept is thermally characterized by thermocouple and infrared measurements. Furthermore the system was tested in a commercial hot embossing equipment to demonstrate the improvements. It could be shown that a cycle time between one and two minutes is possible, in comparison to cycle times of fifteen minutes in conventional hot embossing systems. Although the test system was not optimized so far, in the embossing tests all items were replicated correctly and the microfluidic function was ensured. The results of the research work are applicable also for the optimization of injection molding tool systems.

关键词： Microfluidics

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Intrinsic manufacture and design of positive locking fibre reinforced thermoplastic metal hollow structures 17

Intrinsic manufacture and design of positive locking fibre r...

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17th European Conference on Composite Materials, ECCM 2016

作者： Barfuss, D. Grützner, R. Garthaus, C. Gude, M. Institute of Lightweight Engineering and Polymer Technology Technische Universität Dresden Holbeinstr. 3 Dresden01307 Germany Fraunhofer-Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany

ISBN: (纸本)9783000533877

In contrast to common and classical joining technologies for composite metal hybrid structures such as bonding and riveting, profile and contour joints offer promising potential for novel lightweight structures. First and foremost, joining systems with a form closure function enable to pass very high loads into rod- and tube-shaped fibre reinforced structures, whereby a high degree of material utilization for composite parts can be achieved. This paper presents an intrinsic manufacturing approach for the efficient production of carbon fibre reinforced thermoplastic hollow composite structures with multi scale structured metallic load introduction elements. © 2016, European Conference on Composite Materials, ECCM. All rights reserved.

关键词： Manufacture

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Task-based Motion Control of Digital Humans for Industrial Applications

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Procedia CIRP 2017年 62卷 535-540页

作者： Luigi Pelliccia Franziska Klimant Agostino De Santis Giuseppe Di Gironimo Antonio Lanzotti Andrea Tarallo Matthias Putz Philipp Klimant Institute for Machine Tools and Production Processes Technische Universität Chemnitz Reichenhainer Str. 70 09126 Chemnitz Germany PRISMA Lab DIETI Università degli studi di Napoli Federico II Via Claudio 21 80125 Napoli Italy Joint Lab IDEAS DII Università degli studi di Napoli Federico II P.le Tecchio 80 80125 Napoli Italy Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Reichenhainer Str. 88 09126 Chemnitz Germany

Nowadays digital substitutes of human beings (digital humans), capable of interacting with digital mock-ups in Virtual Reality, are widely used in many fields of engineering (e.g. ergonomics, product design, maintenance, and training). Nevertheless, the animation process of digital humans is still a time-consuming task, and its accuracy and reliability strongly depend on the experience and the skills of the operator. This paper presents an innovative algorithm capable of significantly speeding up the animation process of digital humans, allowing the operator to focus only on the so-called “task-related control points”. This approach allows also to easily conduct biomechanical analyses. The algorithm has been tested with reference to several application scenarios in Virtual Reality.

关键词： Virtual reality Algorithm Kinematics Digital humans

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Energy-efficiency in a Hybrid Process of Sheet Metal forming and Polymer Injection Moulding

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Procedia CIRP 2016年 40卷 109-114页

作者： D. Landgrebe V. Kräusel A. Rautenstrauch A. Albert R. Wertheim Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany Institute for Machine Tools and Forming Technology Technische Universität Chemnitz Reichenhainer Straße 70 09126 Chemnitz Germany

Hybrid processes are an efficient solution for shortening process chains and improving performance. As an example a process combination of sheet metal forming and polymer injection molding is introduced and investigated. The merging of forming and moulding processes into a single step process allows generating potential cost-savings, especially for medium to large production volumes. Based on the technological comparison between the conventional and the new process chain, the determination of the energy consumption and the detected impacts concerning the process efficiency are presented, showing that approx. 20% less energy is required due to using only one tempered tooling and reduction of handling operation.

关键词： forming Energy Efficiency Polymer Moulding Hybrid process

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Investigation of Cooling and Lubrication Strategies for Machining High-temperature Alloys

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Procedia CIRP 2016年 41卷 835-840页

作者： Katja Busch Carsten Hochmuth Bernhard Pause Andrea Stoll Rafael Wertheim Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany NILES – SIMMONS Industrieanlagen GmbH Zwickauer Straße 355 09117 Chemnitz Germany

Optimal and efficient machining of high-temperature alloys is one of the main goals set by the manufacturing technology today, taking into account the unique properties of these materials, the required performance and the process parameters. One of the most important parameters investigated and presented in this paper is the optimal cooling and lubrication strategy. The application of various hybrid cooling strategies such as high-pressure cooling, cryogenic cooling and aerosol dry lubrication offers the potential to extend profitability and energy efficiency as well as high performance and improved surface integrity. The paper introduces fundamental functions, cooling systems and relationships that characterize the efficient utilization on standard machine tools. Based on fundamental investigations conducted using high-temperature alloys with poor machinability such as Titanium alloy Ti6Al4 V and Inconel 718, relevant influencing parameters are derived and optimization options are presented for the cooling strategies.

关键词： Turning cryogenic machining high-pressure cooling

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Process Monitoring of Abrasive Waterjet Formation

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Procedia CIRP 2016年 46卷 43-46页

作者： M. Putz M. Dittrich M. Dix Technische Universität Chemnitz Institute for Machine Tools and Production Processes (IWP) Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Difficult to machine materials require innovative processing solutions for a stable and high quality contouring process of complex forms. Abrasive waterjet cutting gains in importance due to the continuous development of novel high performance materials and multi-material components. A reliable process monitoring during the machining operation becomes essential to avoid waste production. However, the measurement of the process conditions during abrasive waterjet cutting is difficult based on the rough environment inside the machining zone. In this paper appropriate methods for in-process monitoring of the jet conditions, in particular the critical nozzle wear as well as other process output parameters are being tested, discussed and classified.

关键词： Waterjet machining In-process measurement Monitoring

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Simulation-based Correction Approach for Thermo-elastic Workpiece Deformations During Milling Processes

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Procedia CIRP 2016年 46卷 103-106页

作者： J. Glänzel R. Herzog S. Ihlenfeldt A. Meyer R. Unger Fraunhofer Institut for Machine Tools and Forming Technology IWU Chemnitz Germany Technische Universität Chemnitz Chemnitz Germany Technische Universität Dresden Dresden Germany

Based on the method of adaptive finite elements (FEM) a correction approach has been considered to identify the influence of thermo-elastic workpiece deformations during the production process milling. The paper presents a simulation-based tolerance variation calculation of cutting paths, which is caused by the heat input of the machine tool. Therefore a mathematical method is developed to numerically depict the progress of the miller with different curves A(t), B(t) and C(t). These curves are used to map the state of the milling path during the production process as well as to compare the current workpiece contour and the target workpiece contour. The tool center point (TCP) correction results from mapping of time-dependent deformation fields from the FE simulation. The aim is, on the one hand, to make statements before the production about keeping the tolerance, and on the other hand, to derive other correction approaches for the adaption of the cutting path coordinates.

关键词： milling tolerancing material removal thermo-elastic adaptive FEM

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Characteristic Diagram Based Correction Algorithms for the Thermo-elastic Deformation of machine tools

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Procedia CIRP 2016年 41卷 801-805页

作者： Christian Naumann Ilka Riedel Steffen Ihlenfeldt Ulrich Priber Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Chemnitz University of Technology Department of Mathematics Reichenhainer Straße 41 09126 Chemnitz Germany

This paper presents a characteristic diagram based approach to the correction of thermally induced tool center point displacements of machine tools. The entire process from the introduction of the correction principle to the issues arising in the online capable application of this correction method will be discussed, with special focus on the improvement and optimization of the calculation, input selection and grid structures of the characteristic diagrams.

关键词： Thermal error machine tool Correction Tool center point Regression Temperature field Characteristic diagram Smoothed Grid Regression

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Manufacturing of high added value titanium components. A South African perspective

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IOP Conference Series: Materials Science and Engineering 2018年第1期430卷

作者： D Dimitrov E Uheida G Oosthuizen D Blaine R Laubscher A Sterzing P Blau W Gerber O F R A Damm Department of Industrial Engineering Faculty of Engineering Stellenbosch University South Africa Department of Mechanical and Mechatronic Engineering Faculty of Engineering Stellenbosch University South Africa Department of Mechanical Engineering University of Johannesburg South Africa Fraunhofer Institute for Machine Tools and Forming Technology Germany Aerosud Aviation South Africa

South Africa has significant titanium reserves and is developing strategies to not only provide this raw material on global markets, but to manufacture complex titanium alloy products and participate fully in global supply chains. Pursuing more sustainable process chains, manufacturers are constantly striving to enhance the resource efficiency of their high added value processes. Titanium alloys are used comprehensively in aerospace and biomedical applications, due to its favourable strength-to-weight ratio, corrosion resistance and biocompatibility. These properties, however, contribute to the manufacturing challenges, classifying it as a difficult-to-machine material. Various input factors affect the efficiency of a hybrid process chain. The objectives of this multidisciplinary research group were to demonstrate the reduction of material wastage by up to 50% and machining time up to 20% for selected titanium components. The results clearly demonstrate the ability to increase the technology readiness levels of the selected components and to develop competitive hybrid titanium process chains that will enable South Africa to integrate more into global manufacturing value chains.

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