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Evaluation of the Technical-Economic Potential of Particle- Reinforced Aluminum Matrix Composites and Electrochemical Machining

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

作者： A Schubert U Götze M Hackert-Oschätzchen N Lehnert F Herold G Meichsner A Schmidt Technische Universität Chemnitz Professorship Micromanufacturing Technology Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Technische Universität Chemnitz Professorship of Management Accounting and Control Chemnitz Germany franziska.herold@wirtschaft.tu-chemnitz.de

Compared to conventional cutting, the processing of materials by electrochemical machining offers some technical advantages like high surface quality, no thermal or mechanical impact on the work piece and preservation of the microstructure of the work piece material. From the economic point of view, the possibility of process parallelization and the absence of any process-related tool wear are mentionable advantages of electrochemical machining. In this study, based on experimental results, it will be evaluated to what extent the electrochemical machining is technically and economically suitable for the finish-machining of particle- reinforced aluminum matrix composites (AMCs). Initial studies showed that electrochemical machining - in contrast to other machining processes - has the potential to fulfil demanding requirements regarding precision and surface quality of products or components especially when applied to AMCs. In addition, the investigations show that processing of AMCs by electrochemical machining requires less energy than the electrochemical machining of stainless steel. Therefore, an evaluation of electrochemically machined AMCs - compared to stainless steel - from a technical and an economic perspective will be presented in this paper. The results show the potential of electro-chemically machined AMCs and contribute to the enhancement of instruments for technical-economic evaluations as well as a comprehensive innovation control.

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New Feature Extraction and Processing Methods for the Advanced Knowledge Based Process Planning of forming Operations

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Procedia CIRP 2015年 28卷 16-21页

作者： R. Neugebauer M. Werner M. Pröhl G. Brunnett T. Kühnert Fraunhofer Gesellschaft zur Förderung angewandter Forschung e. V. Postfach 20 07 33 80007 Munich Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany Department of Computer Science Technische Universität Chemnitz Straße der Nationen 62 09107 Chemnitz Germany

A new method for the automated extraction, recognition and interpretation of forming features is presented. The motivation is to apply knowledge based engineering (KBE) methods more intensively on process planning procedures for forging, tube hydroforming and sheet metal forming. With a new thinning method three-dimensional (3D) CAD data is reduced to a 1D skeleton graph. By curvature based segmentation of the surface and the neighborhood relations further information are provided. Depending on the gained classification, analyzing algorithms can be performed again with an adapted level of detail. Herewith the process planning can be supported on a much higher level than before. Video abstract Download : Download video (3MB)

关键词： Feature extraction Knowledge based engineering Process planning forming operations Forging Tube hydroforming Sheet metal forming

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Real 3D geometry and motion data as a basis for virtual design and testing 19

Real 3D geometry and motion data as a basis for virtual desi...

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19th CIRP Design Conference: Competitive Design

作者： Weidlich, D. Zickner, H. Riedel, T. Böhm, A. Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Strasse 70 D-09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Reichenhainer Strasse 88 D-09126 Chemnitz Germany

ISBN: (纸本)9780955743641

A consistent and accurate digital data model takes a major role during the whole product life cycle of production facilities. This article introduces both technologies: 3D laser scanning for acquisition of 3D geometry date and motion capturing for real motion data with focus on the application in the product life cycle of production facilities. It gives an overview and comparison of different hard- And software solutions. Workflows for concrete tasks in the planning process show how both technologies can be combined and how the acquired data needs to be handled for the integration with CAD tools or Virtual Reality systems. Finally this article gives an outlook on the possible future development of these technologies. © Cranfield University 2009.

关键词： Virtual reality

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Analysis of strategies for gap control in jet electrochemical machining 14

Analysis of strategies for gap control in jet electrochemica...

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14th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2014

作者： Hackert-Oschätzchen, Matthias Martin, André Meichsner, Gunnar Schubert, Andreas Faculty of Mechanical Engineering Technische Universität Chemnitz Chemnitz09107 Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz09126 Germany

ISBN: (纸本)9780956679031

Electrochemical Machining (ECM) is a promising micro-production technique for the creation of complex and highly accurate three-dimensional geometries in electrically conductive materials. As the electrochemical dissolution behavior is independent from the material's mechanical characteristics like hardness and ductility, ECM is an alternative processing technique to create micro-structures even in mechanically hard to machine alloys. The basic principle of ECM is the anodic dissolution of work piece material by electric charge transport. As a special procedure electrochemical machining with continuous electrolytic free jet (Jet-ECM) offers the possibility to machine work pieces at extremely high current densities up to 1000 A/cm2 [1,2]. In Jet-ECM the electrolyte is pumped continuously through a micro nozzle and ejected with an average speed of approximately 20 m/s perpendicularly to the work piece surface. Thus, a free jet is formed on the surrounding atmospheric air, which leads to a high localization of the current density and therefore to a highly localized machining area around the impinging jet. From the previous work on Jet-ECM the working gap was detected as a significant process variable, which needs an adequate control or adjustment. In this study, an analysis of potential strategies to control this variable is summarized.

关键词： Electrolytes

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On the development of an intrinsic hybrid composite

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

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 Faculty of Mechanical Engineering Technische Universität Chemnitz D-09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology D-09126 Chemnitz Germany Professorship of Materials and Surface Engineering Institute of Materials Science and Engineering Technische Universität Chemnitz D-09125 Chemnitz Germany Chair of Materials Science Institute of Materials Science and Engineering Technische Universität Chemnitz D-09125 Chemnitz Germany

Hybrid parts, which combine low weight with high strength, are moving into the focus of the automotive industry, due to their high potential for usage in the field of crash-relevant structures. In this contribution, the development of an intrinsic hybrid composite is presented, with a focus on the manufacturing process, complex simulations of the material behaviour and material testing. The hybrid composite is made up of a continuous fibre- reinforced plastic (FRP), in which a metallic insert is integrated. The mechanical behaviour of the individual components is characterised. For material modelling, an approach is pointed out that enables modelling at large strains by directly connected rheological elements. The connection between the FRP and the metallic insert is realised by a combination of form fit and adhesive bonds. On the one hand, adhesive bonds are generated within a sol gel process. On the other hand, local form elements of the metallic insert are pressed into the FRP. We show how these form elements are generated during the macroscopic forming process. In addition, the applied sol gel process is explained. Finally, we consider design concepts for a specimen type for high strain testing of the resulting interfaces.

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Electromagnetic Joining of Hybrid Tubes for Hydroforming

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Procedia CIRP 2014年 23卷 1-6页

作者： Verena Psyk Thomas Lieber Petr Kurka Welf-Guntram Drossel Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany

Joining of functionally adapted and weight-optimized semi-finished parts by electromagnetic compression is investigated taking into account that the resulting component is further processed by hydroforming. For this purpose both ends of an aluminum tube are connected to steel tubes. During the subsequent hydroforming of the hybrid tube the joints are exposed to extreme loading. Finite-Element-Simulation is applied for characterizing and quantifying these loads. The electromagnetic joining process is analyzed, the joints are characterized by microstructural analysis and the resulting properties of the joint are evaluated by model experiments.

关键词： Electromagnetic forming joining hydroforming

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High Performance of Machining Processes by Applying Adaptronic Systems

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Procedia CIRP 2014年 14卷 500-505页

作者： W.-G. Drossel A. Bucht C. Hochmuth A. Schubert A. Stoll J. Schneider R. Schneider Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Technische Universität Chemnitz Institute for Machine Tools and Production Processes Reichenhainer Str.70 09126 Chemnitz Germany

Manufacturing processes are constantly facing the demand for higher efficiency regarding time, costs and resource consumption. In addition, challenges arise from the use of new materials and stricter requirements concerning the efficiency of the final product in use. Besides the economic perspective of realizing a highly efficient production and sustainable products, a new level of standards is set by politics and industry. To meet these demands, it may no longer suffice to improve processes by optimizing process parameters. Instead, advanced machine and tool concepts will be necessary and therefore have to be developed. An innovative approach to enhance the cutting process is the integration of adaptronic systems. This integration can happen at different levels, from no close loop control to using additional feed drives and in the cutting tool or in the machine. The paper presents examples from research at fraunhofer iwu for the application of adaptronic systems in machining processes, such as ultrasonic assisted machining, adaptronic form honing and adaptive spindle support for precision finishing of cylinder bores. Properties of the actuators and the adaptronic systems are described and the effects on both, the efficiency of the machining process and the final product performance, are discussed.

关键词： Adaptronic form honing Adaptive spindle support Ultrasonic assisted machining Hybrid processes

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Load-dependent Optimization of Honeycombs for Sandwich Components – New Possibilities by Using Additive Layer Manufacturing

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Physics Procedia 2014年 56卷 327-335页

作者： Fabian Riss Johannes Schilp Gunther Reinhart Fraunhofer Institute for Machine Tools and Forming Technologies (IWU) Project Group for Resource-efficient Mechatronic Processing Machines (RMV) Beim Glaspalast 5 86153 Augsburg Germany

Due to their feasible geometric complexity, additive layer manufacturing (ALM) processes show a highpotential for the production of lightweight ***, ALM processes enable the realization of bionic-designedcomponents like honeycombs, which are optimized depending upon load and outer boundary *** optimization is based on a closed-loop, three-steps methodology: At first, each honeycomb is conformed to the surface of the part. Secondly, the structure is optimizedfor lightweight *** is possible to achieve a homogeneous stress distribution in the part by varying the wall thickness, honeycombdiameter and the amount of honeycombs, depending on the subjected stresses and strains. At last, the functional components like threads or bearing carriers are integrated directly into the honeycomb *** all these steps as an iterative process, it is possible to reduce the mass of sandwich components about 50 percent compared to conventional approaches.

关键词： honeycombs sandwich components load-dependency additive manufacturing telegraphing-effect snap-in connections

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Serial Production of Cellular Structures – No Additives Allowed!

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Procedia Materials Science 2014年 4卷 57-62页

作者： Christian Hannemann Steffen Scholz Department of Lightweight Design Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Strasse 88 09126 Chemnitz Germany

As reported before, the Lightweight design department of the fraunhofer institute iwu is collaborating with several foundries in manifold projects. The objectives show a large variety starting with energy management activities and leading to product and technology development. Especially in high pressure die casting, most of the products are material minimized till the edge of the castability. The wall thickness is decreased to their very limits, holes are integrated for lightweight reasons and structures modified by topology optimization pushing this traditional industrial sector to the newest state of technology. Many attempts have been published trying to combine that high level serial production technology with the cellular structures for lightweight reasons on the one hand and for material efficiency on the other. Anyway, till now none of them is dealing with real serial die casting parts. The geometry of the parts needs to be adapted to the requirements of the pore generation procedure. As these approaches are rather complex, in some cases the invested energy, time and additives consume the savings reached by the pore integration. The intention of the project is based upon the omnipresent resource efficiency. By intensive technological investigation of the state of the art and several practical test runs, almost all published strategies of pore generation in high pressure die casting have been analyzed. The industrial partner of the project rejected all of the current approaches as irrelevant for serial application forcing us to create new ideas. Differing from common metal foam structures the objected material savings are around 20-25%. By changing the die-casting-machine setup and several parameters the first parts in original geometry have been realized reaching the target of material reduction. Mostly homogenous pores have been integrated in common serial parts containing a wall thickness of below 3 mm while the outer shell is still completely closed and

关键词： High-pressure-die-casting defined porosity castings resource efficiency serial production

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A Reconfigurable Tooling System for Producing Plastic Shields

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Procedia CIRP 2014年 17卷 853-858页

作者： Dominik Simon Lisa Kern Julia Wagner Gunther Reinhart Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Project Group Resource-efficient Mechatronic Processing Machines Beim Glaspalast 5 86153 Augsburg Germany Technische Universität München (TUM) Institute for Machine Tools and Industrial Management (iwb) Boltzmannstrasse 15 85748 Garching Germany

State of the art for producing 3-dimensional formed plastic shields is the use of mould blocks that are milled on machining centers. This paper describes the replacement of traditional mould blocks by a novel automated reusable mould and tooling system that produces good forming results at low investment costs. The reconfigurable tooling system replaces commonly used mould blocks. Two major issues will be addressed. The first aim is to identify principles for low tooling costs, while the second focuses on the improvement of a forming process suitable for the system so that this can be used for a broad range of products.

关键词： flexible forming reconfigurable tooling system thermoforming plastic shields

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