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Energy Visualization Techniques for machine tools in Virtual Reality

Procedia CIRP 2016年 41卷 329-333页

作者： Luigi Pelliccia Philipp Klimant Marco Schumann Franziska Pürzel Volker Wittstock Matthias Putz Institute for Machine Tools and Production Processes Technische Universität Chemnitz Reichenhainer Str. 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Reichenhainer Str. 88 09126 Chemnitz Germany

Energy-efficient machine tools are becoming a more and more important factor for competitive manufacturing processes. However, there is still a lack of appropriate visualization techniques that effectively support engineers and scientists to consider energy as an additional optimization and decision parameter in machine tool design and manufacturing. Virtual Reality has become an effective technology able to visualize very complex systems, providing the users with a high level of immersion and interactivity. For this reasons, a great deal of research activity has recently been focused on the development of advanced Virtual Reality-based visualization techniques capable of representing the energy flow through the machine tools in a clear and intuitive manner. This paper presents three different Virtual Reality-based energy visualization methods and a comparison of them based on a short user survey. In addition to 2D Billboard and 3D Sankey diagram, an innovative energy visualization technique based on 3D particle systems will be explained in detail. All three visualization methods have been implemented in one Virtual Reality model of a specific machine tool. The energy values have been determined from real measurements carried out directly on the real machine tool. This allowed a comparison of the three methods by means of their usability and understanding. Therefore a short user survey has been conducted in order to determine the advantages and disadvantages as well as improvement potential of the three visualization methods from the user's point of view.

关键词： Virtual reality machine tool Energy efficiency Energy visualization

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Influence of process induced damages on joint strength when self-pierce riveting carbon fiber reinforced plastics with aluminum 18th

Influence of process induced damages on joint strength when ...

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18th International ESAFORM Conference on Material forming, ESAFORM 2015

作者： Landgrebe, Dirk Jäckel, Mathias Niegsch, Ronald Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01189 Germany

ISBN: (纸本)9783038354710

The importance of environment friendly mobility strengthens the need of lightweight design in the automotive industry. New electric car models, like the BMW i3, already have car body with a high amount of carbon fiber reinforced plastics (CFRP) to allow, as a result of the low vehicle weight, appropriate ranges without reloading the battery. Methods for joining materials like CFRP play a key role to implement lightweight designs into car body production. Conventional joining methods like spot welding cannot be used for such material combinations. Due to the good automation and possible combination with adhesive, mechanical joining techniques such as selfpierce riveting (SPR) are very relevant for joining these lightweight materials. While generally selfpierce riveting of CFRP with aluminium is possible, different damages e.g. delaminations, fiber or matrix fractures in the CFRP can occur during the joining process and have to be considered. This paper shows an analysis of these process induced damages when self-pierce riveting CFRP compound with aluminum sheet metal and investigates their influence on the joint strength. In our research the conventional SPR process of CFRP-aluminium joints is compared to the application of a new die concept for SPR in which a separated die is used to reduce the process induced delaminations in the CFRP. Additionally, these joining results are contrasted to SPR joints with predrilled CFRP components. Through the pre-drilling the damages in the CFRP can nearly be avoided completely and so these joints can be used as a reference. The results of the three processes to produce CFRP-aluminum joints are compared by micrographs, computed tomography and strength tests. © (2015) Trans Tech Publications, Switzerland.

关键词： Carbon fiber reinforced plastics

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Process combination of hydroforming and injection moulding for the insitu manufacturing of metal and plastic composite structures 20th

Process combination of hydroforming and injection moulding f...

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20th Symposium on Composites, 2015

作者： Albert, André Drossel, Welf-Guntram Zorn, Wolfgang Nendel, Wolfgang Raithel, Dirk Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Technische Universität Chemnitz Chemnitz Germany

ISBN: (纸本)9783038355151

The use of lightweight structures is a major trend in the reduction of fuel consumption and CO2 emissions, especially in transport. Metal plastic hybrid structures are an efficient solution to use the best material at every point in the design space. In the state of the art production technologies, the metal parts are produced separately from the plastic parts. The injection moulding process is only used for forming the plastic parts and for joining. These process chains are very extensive. The article shows the development of new process combinations. The aim is a combination of metal forming and injection moulding in one die and one process. One part should be produced with every single stroke of the press. In the first step, deep drawing, injection molding and media based forming with the plastic melt were successfully merged in one tool and one process. It was possible to integrate the injection moulding process into a deep drawing machine. In the next step, it was possible to successfully combine hydroforming and injection molding. For this process combination the hydroforming process is integrated into an injection moulding press. Different surface structures of the metal tubes, such as sandblasting, knurling and laser structuring, were systematically tested regarding to their properties as an adhesion promoter. The target is to establish a purely mechanical connection between the hydroformed metal component and the injection moulded component from glass fibre reinforced plastic instead of the chemical bonding agents often used previously, such as Vestamelt®. © (2015) Trans Tech Publications, Switzerland.

关键词： Metals

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Development of a Dynamic Substructuring Framework to Facilitate in Situ Machining Solutions Using Mobile machine tools

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Procedia Manufacturing 2015年 1卷 756-767页

作者： Mohit Law Hendrik Rentzsch Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

In situ machining of large parts using mobile machines that are moved to part location(s) allows these parts to be machined, repaired and maintained directly on the site of operation. However, every new part and location that the machine is moved to results in different boundary conditions for the machine-part system which singularly influences the dynamics of the combined system and makes for difficult planning of first-time right machining solutions. To facilitate the planning of in situ machining solutions, this paper presents a dynamic substructuring framework that can predict assembled system dynamics by combining measured and/or modelled substructural response of the individual components under varying base/part/contact/configuration characteristics. Substructural coupling is formulated in the frequency and the continuous-time domains for representative examples of the mobile machine being connected to two different part/base models. The frequency based substructuring approach is used to predict tool point dynamics, results of which are instructive for designing of machining strategies to ensure stable productive cutting conditions. State-space substructural coupling predicts the changing nature of the plant model under the varying influences, which provides guidelines for designing appropriate control strategies and selection of appropriate CNC control parameters. Methods presented aid establishment of experimental guidelines for planning of first-time right in situ machining solutions.

关键词： Dynamic substructuring mobile machine tool in situ machining varying boundary conditions receptances state-space coupling modular synthesis mutability

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Fast Determination of the Material Removal Characteristics in Pulsed Electrochemical Machining

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Procedia CIRP 2016年 46卷 123-126页

作者： G. Meichsner M. Hackert-Oschätzchen M. Krönert J. Edelmann A. Schubert M. Putz Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany Professorship Micromanufacturing Technology Faculty of Mechanical Engineering Technische Universität Chemnitz 09107 Chemnitz Germany

Electrochemical machining (ECM) of metallic materials is a complex manufacturing process. Currently the design of the process parameters and the cathode geometry is determined by expensive and inefficient experiments. This paper introduces a method for a fast determination of the material removal characteristics in pulsed electrochemical machining (PECM). The determination is performed by help of removal experiments using a PEMCenter 8000. As example the material removal characteristics of stainless steel 1.4301 under PECM conditions are shown. Based on the resulting mathematical description of the material removal characteristics a design of PECM processes by analytical calculations or multiphysics simulation is feasible.

关键词： electrochemical machining precise electrochemical machining localized anodic dissolution material removal characteristics

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Mechanical joining of materials with limited ductility: Analysis of process-induced defects

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AIP Conference Proceedings 2017年第1期1896卷

作者： M. Jäckel S. Coppieters M. Hofmann N. Vandermeiren D. Landgrebe D. Debruyne T. Wallmersberger K. Faes 1Fraunhofer Institute for Machine Tools and Forming Technology IWU (Dresden Germany) 2KU Leuven Technology Campus Ghent Department of Materials Engineering (Ghent Belgium) 3TU Dresden Institute for Solid Mechanics (Dresden Germany) 4Belgium Welding Institute (Ghent Belgium)

The paper shows experimental and numerical analyses of the clinching process of 6xxx series aluminum sheets in T6 condition and the self-pierce riveting process of an aluminum die casting. In the experimental investigations the damage behavior of the materials when using different tool parameters is analyzed. The focus of the numerical investigations is the damage prediction by a comparison of different damage criteria. Moreover, strength-and fatigue tests were carried out to investigate the influence of the joining process-induced damages on the strength properties of the joints.

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Process combinations for the manufacturing of metal-plastic hybrid parts

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IOP Conference Series: Materials Science and Engineering 2016年第1期118卷

作者： W-G Drossel C Lies A Albert R Haase R Müller P Scholz Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

The usage of innovative lightweight materials and processing technologies gains importance in manifold industrial scopes. Especially for moving parts and mobility products the weight is decisively. The aerospace and automotive industries use light and high-strength materials to reduce weight and energy consumption and thereby improve the performance of their products. Composites with reinforced plastics are of particular importance. They offer a low density in combination with high specific stiffness and strength. A pure material substitution through reinforced plastics is still not economical. The approach of using hybrid metal-plastic structures with the principle of 'using the right material at the right place' is a promising solution for the economical realization of lightweight structures with a high achievement potential. The article shows four innovative manufacturing possibilities for the realization of metal-plastic-hybrid parts.

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Micro structuring of coated tools for dry Sheet metal forming of aluminium alloys 15

Micro structuring of coated tools for dry Sheet metal formin...

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

作者： Börner, Richard Scholz, Peter Kühn, Ralf Schubert, Andreas Zeidler, Henning Müller, Roland Technische Universität Chemnitz Prof. Micromanufacturing Technology Chemnitz09107 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz09126 Germany

ISBN: (纸本)9780956679079

Sheet metal forming is characterised by strong frictional forces involving an increase of the temperature and a tendency to adhesion. Consequently, use of lubricants is essential yet, especially for forming of Aluminium alloys. Furthermore, lubricant reduces tool wear. However, for economical and ecological reasons, dry forming is highly desired. Avoiding the application of lubrication requires a reduction of the coefficient of friction and the tendency for adhesion in dry forming processes. One approach is to increase the nominal surface pressure by micro structuring the tool. Additionally, different carbon based layers (a-C:H:Si and CVD diamond) are applied on the tool to reduce wear and tendency to adhesion. For using a a-C:H:Si layer, uncoated steel drawing tools are micro structured with calottes by milling. Because of a higher thickness of CVD diamond layers, calottes have to be generated directly in the coating using ablating processes like electrical discharge machining. To emulate the tribological system of a sheet metal forming process and characterise it, strip drawing tests are done. For a-C:H:Si coated drawing tools, the test results show a significant reduction of the coefficient of friction in micro structured, compared to polished drawing tools. To further increase the wear resistance of the tool it is intended to apply CVD diamond layers on steel tools as soon as the process is operational.

关键词： Metals

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Surface Finish Machining of Medical Parts Using Plasma Electrolytic Polishing

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Procedia CIRP 2016年 49卷 83-87页

作者： Henning Zeidler Falko Boettger-Hiller Jan Edelmann Andreas Schubert Technische Universität Chemnitz Professorship Micromanufacturing Technology Reichenhainer Str. 70 09126 Chemnitz Germany Beckmann-Institut für Technologieentwicklung e.V. Turleyring 15 09376 Oelsnitz/E. Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Biomanufactured parts, for implant or generally in-vivo use, have high requirements for surface properties. Depending on their field of application, not only smooth, but also well-defined surfaces, i.e. roughness parameters, must be set to allow for the respective functionalities such as optimal cell growth or minimal friction and wear. While for many parts mechanical polishing procedures are state-of-the-art, which are time-consuming and limited in their flexibility, established electrolytic polishing processes often incorporate aggressive media such as acids. Plasma electrolytic Polishing (PeP), a high-voltage process combining anode dissolution and plasma-chemical processes, can be considered a suitable alternative. The paper focusses on current investigations of PeP and shows application scenarios, also pointing out necessary development directions to introduce PeP to industrial biomanufacturing process chains.

关键词： Plasma electrolytic Polishing PeP surface functionalisation polishing

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Hot metal gas forming of titanium grade 2 bent tubes

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AIP Conference Proceedings 2017年第1期1896卷

作者： Alexander Paul Markus Werner Ricardo Trân Dirk Landgrebe 1Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 D-09126 Chemnitz Germany 2TU Bergakademie Freiberg Institute of Metal Forming Bernhard-von-Cotta-Straße 4 D-09599 Freiberg Germany

Within the framework of investigations, an exhaust gas component made of Titanium Grade 2 was produced by means of Hot Metal Gas forming (HMGF) at the fraunhofer iwu in Chemnitz, *** semi-finished products were two-fold bent, thermal joined, calibrated and pre-formed tubes. So far, a three-stage internal high-pressure forming process at room temperature plus two necessary intermediate heat treatments were used to produce the component. Due to its complexity as well as the limited forming ability of Titanium Grade 2 at room temperature an one step Hot Metal Gas forming was developed to replace the former procedure.

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