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The Interface of an Intrinsic Hybrid Composite – Development, Production and Characterisation

Procedia CIRP 2017年 66卷 289-293页

作者： R. Kießling J. Ihlemann M. Riemer W.-G. Drossel I. Scharf T. Lampke S. Sharafiev M. Pouya M.F.-X. Wagner Professorship of Solid Mechanics Chemnitz University of Technology Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Reichenhainer Str. 88 09126 Chemnitz Germany Professorship of Materials and Surface Engineering Chemnitz University of Technology Erfenschlager Str. 73 09125 Chemnitz Germany Professorship of Material Science Chemnitz University of Technology Erfenschlager Str. 73 09125 Chemnitz Germany

Due to a combination of different classes of materials, intrinsic hybrid composites are characterised by high strength and low weight. The mechanical properties of hybrid parts are mainly determined by the interface between the different materials. Consequently, this interface has to be considered in detail within the development of an intrinsic hybrid composite. The general approach of the considered composite is the combination of a mechanical form fit with adhesive bonding. This contribution focuses on the development, production and characterisation of the interface between aluminium and a fibre reinforced polymer as well as of the hybrid composite.

关键词： hybrid composite interface mechanical interlocking cohesive bonding crash performance

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Target Systems and Decision-making to Increase Production Sustainability

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Procedia CIRP 2016年 48卷 34-39页

作者： Matthias Putz Uwe Götze Johannes Stoldt Enrico Franz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Chair of Management Accounting and Control Technische Universität Chemnitz Professur BWL III 09107 Chemnitz Germany

Many industrial companies are trying to improve their operation's sustainability. However, these efforts towards change are usually governed by economic considerations. This serves to neglect or at least diminish the perceivable relevance of ecologic or social consequences for investigated alternatives. This paper discusses the implications of multi-criterial target systems which extend the scope of considerations beyond economics to support the realisation of proactive environmental strategies. A special focus is set on the definition of targets as well as decision-making in brown-field planning projects. The findings are applied in a simulation-based study on the parameterisation of an energy-sensitive production control strategy.

关键词： Target systems Brown-field planning projects Sustainability Energy-sensitive production strategy Multi-objective genetic algorithm NSGA-II

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Tool Technologies for Milling of Hardmetals and Ceramics

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Procedia CIRP 2016年 46卷 299-302页

作者： Thomas Bergs Volkmar Richter Michael Ottersbach Johannes Pötschke Carsten Hochmuth Katia Busch Fraunhofer Institute for Production Technology IPT 52074 Aachen Germany Fraunhofer Institute for Ceramic Technologies and Systems 01277 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

Hardmetals and ceramics are major substrate materials for a wide range of cutting tools and forming dies. Due to their high specific hardness the final part geometry is usually obtained by sintering of preformed green parts, electrical discharge machining, grinding and/or polishing. Machining by milling is not possible due to fast and unpredictable milling tool failures. To enable milling for tungsten carbides and ceramics new tool technologies are developed. The technologies encompass nanoscaled tungsten carbide hardmetals, innovative coating systems, new milling tool designs as well as adapted milling processes. By combining these technologies it becomes possible to mill different grades of hardmetals and ceramics with hardness values over 1200 HV10.

关键词： Milling cutting ultrafine cemented carbides nanoscaled cemented carbides hard machining

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A Framework for Information-driven Manufacturing

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Procedia CIRP 2016年 57卷 38-43页

作者： Marko Friedemann Thies Uwe Trapp Johannes Stoldt Tino Langer Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technologies IWU Reichenhainer Straße 88 09126 Chemnitz Germany Robert Bosch GmbH Bexbacher Straße 72 66424 Homburg (Saar) Germany

Despite the ever increasing saturation of manufacturing with information and communication technologies, most collected data is only used for its original purpose. This limits the potential of this data because it is almost never analysed for more complex information. The SmARPro project aims to provide solutions for exposing equipment data, analysing linked data sources and bringing helpful information to the shop floor. This paper presents the underlying framework, which formalises the structure of the SmARPro system and provides the foundation of information-driven manufacturing. Its application is exemplified in a case study, in which traceability data is used for productivity analysis.

关键词： Manufacturing data SmARPro Industry 4.0 Information Overall equipment efficiency

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Granulation of Extruded Plastic Wires – Influence of Tool Geometry and Process Parameters

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Procedia CIRP 2016年 46卷 135-138页

作者： Macario Cardone Matthias Putz Gerhard Schmidt Martin Dix Jürgen Friedrich Erich Stockmann Institute for Machine Tools and Production Processes Chemnitz University of Technology 09010 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany Gebr. Saacke GmbH & Co. KG 75181 Pforzheim Germany Reduction Engineering GmbH 70825 Korntal-Münchingen Germany

Granulators cut extruded elastomer wires in small pieces, which can be used as starting raw material for injection molding. This contribution investigates the most relevant parameters of process and tool geometry for the granulation technology, with the aim of improving process efficiency and granule quality. Fiber-reinforced PA and ABS plastics have been analyzed using a dedicated test bench and finite element simulations. High-speed camera and various sensors were used to investigate the cutting process. The considered geometrical and kinematic parameters have been varied within a broad range in order to determine optimum values.

关键词： Cutting tool Fiber reinforced plastic (FRP) Finite Element Method (FEM) Granulation

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Surface Characterization of Particle Reinforced Aluminum-matrix Composites Finished by Pulsed Electrochemical Machining

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Procedia CIRP 2016年 45卷 351-354页

作者： Matthias Hackert-Oschätzchen Norbert Lehnert André Martin Gunnar Meichsner Andreas Schubert Professorship Micromanufacturing Technology Technische Universität Chemnitz 09107 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

Aluminum matrix composites (AMCs) are difficult to machine conventionally. Pulsed Electrochemical Machining (PECM) is an alternative method to machine AMCs. Metals can be machined without contact, independent of material hardness and without mechanical or thermal impact. During the process no tool wear occurs. The AMCs consist of an aluminum matrix, which is easily to machine with PECM, and SiC-particles, which cannot be dissolved during the electrochemical machining process applying neutral electrolytes. This combination leads to a special behavior of dissolution and anodization. In this study, the influence on the surface layer, caused by Pulsed Electrochemical Machining of AMCs, is analyzed.

关键词： Pulsed Electrochemical Machining Micro machining Particle Reinforced Aluminum ECM

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Improving Performance of Turn-milling by Controlling Forces and Thermally Induced Tool-center Point (TCP) Displacement

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Procedia CIRP 2016年 40卷 481-485页

作者： M. Putz S. Ihlenfeldt U. Karaguzel U. Semmler E. Budak M. Bakkal R. Wertheim Fraunhofer Institute for Machine Tools and Forming Technology IWU 09126 Chemnitz Germany Mechanical Engineering Department Istanbul Technical University 34437 Istanbul Turkey Faculty of Engineering and Natural Sciences Sabanci University 81474 Istanbul Turkey

Improving performance during fine turn-milling operations including accuracy and productivity requires controlling of the cutting forces and the thermally induced displacement of the cutting edge. The objective of this investigation is to determine the thermally induced displacement of TCP during turn-milling and to reduce this displacement by using pressurized cooled air. The forces and tool elongation simulated by FEM are compared to measured values. It was shown that the amount of tool elongation could be 40% of the depth of cut in fine turn-milling, and it is possible to predict the tool elongation by FEM. Furthermore, cooled air can reduce the tool elongation by 65%.

关键词： Thermal effects Machining Finite Element Method (FEM)

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Generation of Defined Surface Waviness on Tungsten Carbide by Jet Electrochemical Machining with Pulsed Current

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Procedia CIRP 2016年 45卷 231-234页

作者： André Martin Christian Eckart Norbert Lehnert Matthias Hackert-Oschätzchen Andreas Schubert Technische Universität Chemnitz Professorship Micromanufacturing Technology 09107 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

Conventional machining of WC6Co carbide metal is challenging due to its mechanical properties. Electrochemical machining applying a continuous free jet and pulsed current (Jet-PECM) is a promising alternative for surface structuring of this material, because the resulting removal only depends on its electrochemical properties. Neither tool wear nor thermal or mechanical influence on the work piece is caused by this process. In this study the influence of current pulse parameters on the cross-sectional shape of straight-lined grooves machined with Jet- PECM in WC6Co was analyzed. Furthermore adequate machining strategies were derived and applied in order to generate surfaces with defined waviness.

关键词： Electrochemical Machining (ECM) Pulsed Electrochemical Machining (PECM) Electrolyte Jet Tungsten Carbide

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Generation of Complex Surfaces by Superimposed Multi-dimensional Motion in Electrochemical Machining

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Procedia CIRP 2016年 42卷 384-389页

作者： Andreas Schubert Matthias Hackert-Oschätzchen André Martin Sebastian Winkler Danny Kuhn Gunnar Meichsner Henning Zeidler Jan Edelmann Professorship Micromanufacturing Technology Faculty of Mechanical Engineering Technische Universität Chemnitz 09107 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany

In electrochemical machining the shape of the machined surface corresponds to the shape of the cathode and the applied electrical charge. In order to increase the flexibility of electrochemical machining for the generation of complicated surfaces, several investigations on the application of superimposed multi-dimensional motion were performed. In this study several possibilities for the application of superimposed multi-dimensional motions are shown and compared concerning the machining flexibility and tooling requirements. Detailed investigations were focused on Jet Electrochemical Machining (Jet-ECM) and Pulsed Electrochemical Machining (PECM). The results are discussed and compared with respect to these applications. The special characteristic of Jet-ECM is the high localization of electric current by continuously applying an electrolyte jet. Based on experiments of manufacturing plane surfaces, the variation of line spacing was derived as a suitable superimposed motion strategy. To realize this strategy, the cross-sectional profiles of planar Jet-ECM erosions were detected. The measured depths of these erosions were implemented in a mathematical model. To evaluate the developed model, various experiments for the generation of different complex surfaces were carried out in four steel materials. It could be demonstrated that the variation of the line spacing is suitable to generate complex surfaces and that the deviations of the produced geometries from the intended geometries are in a range of a few micrometers. In addition PECM, characterized by the application of voltage pulses combined with an oscillating cathode, was investigated. In this study a multi-dimensional motion based on a single-axis tool movement superimposed with a rotation axis is investigated experimentally. The superposition enables the generation of complex surfaces with helical symmetry while preserving the specific benefits of PECM. The machined samples show good surface quality and high di

关键词： jet electrochemical machining pulsed electrochemical machining Jet-ECM PECM closed electrolyte jet localized anodic dissolution motion strategies

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Extending the Scope of Future Learning Factories by Using Synergies Through an Interconnection of Sites and Process Chains

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Procedia CIRP 2016年 54卷 124-129页

作者： Max Weeber Christian Gebbe Max Lutter-Günther J. Böhner J. Glasschroeder R. Steinhilper G. Reinhart Fraunhofer Institute for Manufacturing Engineering and Automation IPA Project Group Process Innovation at Bayreuth University Universitaetsstrasse 30 D-95447 Bayreuth Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Project Group Resource-efficient Mechatronic Processing Machines Beim Glaspalast 5 D-86153 Augsburg Germany

Learning factories serve as platforms to disseminate research findings into industrial practice and to educate prospective engineers in hands-on courses. The number of competences which can be taught in learning factories is related with the number of available processes and machines. A larger number of machines enables for example comparisons between similar processes, the operation of longer process chains and generally speaking a broader curriculum. However, due to financial or space restrictions the investment in machines is often limited. In order to overcome this issue, the collaboration between learning factories through interconnection of process chains is proposed in this paper. A systematic method, by which possible interlinkages can be found, is presented and a case study of the interlinkage of two learning factories in Bayreuth and Augsburg is given.

关键词： Resource efficiency Learning Factory Networks Collaboration CFRP Additive Manufacturing Virtual Learning

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