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Resource and Energy Efficiency in Machining Using High-Performance and Hybrid Processes

Procedia CIRP 2012年 1卷 3-16页

作者： R. Neugebauer W. Drossel R. Wertheim C. Hochmuth M. Dix Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 09126 Chemnitz Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology 09107 Chemnitz Germany

The main goal in manufacturing is to minimize production time, cost, energy and resources while maintaining or even improving performance. The main influence on process efficiency in metal cutting can be related to the machining parameters, while performance also depends on the material behavior such as strain rate, machining temperature and cutting forces. In the past, industry was searching for higher efficiency mainly by using higher production rates, achieved with higher cutting conditions. However, during the last decade the production process chain has been controlled more and more by the near-net-shape of semi-finished components and the use of high performance processes. This paper presents established and new applications of process modifications, substitutions, optimizations as well as the use of hybrid processes. In high performance cutting (HPC) additional elements play an important role, for example tool design and tool material, wear and tool life, coolant strategies, including dry cutting, MQL, cryogenic and high pressure flushing as well as the machine tool properties. Furthermore, this paper presents and discusses examples of the influence of process parameters in turning, milling, drilling, grinding and impact cutting under HPC conditions on the energy and resources efficiency in the automotive, aerospace, dies and moulds, micromachining and heavy duty industries.

关键词： Flushing Hybrid Resources Energy Efficiency

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Light Shape Memory Actuators in Automobiles

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ATZ worldwide 2011年第4期113卷 10-15页

作者： Kunze, Holger Bucht, Andre Pagel, Kenny Zerneke, Arne Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany

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Realistic machine Simulation with Virtual Reality

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Procedia CIRP 2012年 3卷 103-108页

作者： R. Neugebauer P. Klimant M. Witt Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Strasse 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Reichenhainer Strasse 88 09126 Chemnitz Germany

Today highly complex components are manufactured on NC-controlled machine tools. The NC programs, controlling these machines, are usually automatically generated by CAM software. This automatic processing is often erroneous. The VR-based realistic machine simulation, presented in this paper, extends the usual content of a machine simulation, like material removal and collision detection, by various new aspects. The coupling of a real NC unit allows the recognition and elimination of all process- as well as controller-caused errors. The integration of the multi-body simulation enables the consideration of inertia, machine rigidity and milling cutter deflection.

关键词： machine Simulation Multi-Body Simulation Virtual Reality

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Model-based position control of Shape memory alloy actuators

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International Journal of Mechatronics and Manufacturing Systems 2012年第2期5卷 93-105页

作者： Neugebauer, Reimund Pagel, Kenny Bucht, Andre Drossel, Welf-Guntram Department of Adaptronics and Acoustics Fraunhofer Institute for Machine Tools and Forming Technology Nöthnitzer Straße 44 01187 Dresden Germany

Shape-memory-alloys (SMAs) are easy to integrate into mechanical structures and capable of handling high specific workloads. Therefore, SMAs possess an outstanding potential to serve as positioning devices in various applications. We present here the multi-domain modelling of an electrically heated SMA wire which includes changes of electrical parameters in conjunction to mechanical parameters. Due to the correlation between electrical resistance and mechanical stroke, it was possible to implement a resistance-based position control without the necessity of an external positioning sensor. In order to design a linear position controller by common rules, the highly complex and non-linear model was simplified. Controller development yielded a PID algorithm that was implemented on a rapid prototyping system as part of an SMA wire test bench. The models accuracy was verified by various measurements with different wires and multiple loads. Based on that, it was possible to design an actuator which utilises a flexible socket instead of fixed mountings. Copyright © 2012 Inderscience Enterprises Ltd.

关键词： Position control

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Design and Modeling of a self-sufficient Shape-Memory-Actuator

Design and Modeling of a self-sufficient Shape-Memory-Actuat...

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Conference on Active and Passive Smart Structures and Integrated Systems

作者： Bucht, Andre Junker, Tom Pagel, Kenny Drossel, Welf-Guntram Neugebauer, Reimund Fraunhofer-Institute for Machine Tools and Forming Technology IWU (Germany)

ISBN: (纸本)9780819485397

In machine tools several time and position varying heat sources causes complex temperature distributions. The resulting problems are varying thermal deformations which cause a loss of accuracy as well as non optimal drive conditions. An option to deal with that issue is to use structure integrated SM-actuators which use the thermal energy accumulated by machining processes to yield an actuator displacement. That creates a structure inherent control loop. There the shape-memory-elements work as sensing element as well as actuation element. The plant is defined by the thermal and mechanical behaviour of the surrounding structure. Because of the closed loop operation mode, the mechanical design has to deal with questions of stability and parameter adjustment in a control sense. In contrast to common control arrangements this issues can only be influenced by designing the actuator and the structure. To investigate this approach a test bench has been designed. The heat is yielded by a clutch and directed through the structure to the shape memory element. The force and displacement of the actuator are therefore driven directly by process heat. This paper presents a broad mechanical design approach of the test bench as well as the design of the SM-actuator. To investigate the thermo-mechanical behaviour of the structure-integrated actuator, a model of the test bench has been developed. The model covers the thermal behaviour of the test bench as well as the thermo-mechanical couplings of the shape memory actuator. The model has been validated by comprehensive measurements.

关键词： shape-memory-alloy actuator self sufficient structure integrated adaptive ball-screw-drive

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Influence of the steel alloy composition on phase transitions and its applicability to hot forming process

Influence of the steel alloy composition on phase transition...

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10th International Conference on technology of Plasticity, ICTP 2011

作者： Neugebauer, R. Göschel, A. Rautenstrauch, A. Meza-García, E. Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Machine Tools and Forming Technology TU Chemnitz Germany

ISBN: (纸本)9783514007840

Continuous Cooling Transformation (CCT) diagrams determined with a dilatometer were used to analyse the influence of the alloying elements on the phase transitions of high strength steel sheet alloys. Mo and Cr additions showed a significant influence on the extension of the bainitic region, whereas C and B additions showed noteworthy Improvement on the quenchability of these steel alloys. These alloy properties are desirable requirements to be integrated In the hot formed components. Dilatometer samples of the 22MnB5 steel alloy were used to determine the resulting mechanical properties In function of the cooling rate. Hardness and micro-bending tests were carried out and they showed a qualitative trend with the cooling rate, which permits a preliminary estimation of the crash performance. A hot-forming process of a car B-pillar foot was simulated In commercial finite element code LS-DYNA considering experimentally determined Input parameter for the 22MnB5 sheet alloy. These results were evaluated with an experimental trial showing a good approach. Results obtained In this work show an overview of essential research fields for the optimization of the hot forming process for the production of graded components, Including the possibility of Increasing the spectrum of alloys used In this process. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.

关键词： High strength steel

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Machining with redundant kinematics

Machining with redundant kinematics

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ASME 2011 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference, IDETC/CIE 2011

作者： Neugebauer, Reimund Drossel, Welf-Guntram Ihlenfeldt, Steffen Rentzsch, Hendrik Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz 09126 Germany

ISBN: (纸本)9780791854839

The demand for high productivity and quality combined with the need for decreasing energy consumption will substantially affect machine tool design in the future. This development is driven by a modification of process chains which is focused on resource conservation. One important contribution for that purpose is the transition towards complete machining. This approach calls for a configuration targeting major process stability as well as a structure geared towards accuracy and dynamism. The compromise between potential dynamism and machine size can be improved by using redundant drives. This paper describes models, simulation tools and the method of the development process for redundant kinematics. To highlight the different aspects of designing such machine tool structures, their development process is demonstrated on the basis of two examples, complete machining for tool- and die making and an adaptive spindle holder for micro contouring and -structuring. Copyright © 2011 by ASME.

关键词： Energy utilization

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Semantic Web based dynamic energy analysis and forecasts in manufacturing engineering

Semantic Web based dynamic energy analysis and forecasts in ...

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作者： Wenzel, Ken Riegel, Jörg Schlegel, Andreas Putz, Matthias Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (纸本)9783642196911

This paper proposes an approach for supporting the analysis of collected energy consumption data in combination with structured system models to reveal correlations between energy usage and related properties of products, operations and equipment. The described method serves as a starting point for the creation of tailored simulation models for energy consumption forecasts that can be used in the planning phase of manufacturing systems. Therefore several energy-oriented simulation methods are introduced and discussed regarding their suitability for different use cases in manufacturing engineering.

关键词： Energy efficiency

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Property distribution in aluminium material processed by gradation rolling

Property distribution in aluminium material processed by gra...

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10th International Conference on technology of Plasticity, ICTP 2011

作者： Neugebauer, R. Sterzing, A. Zachäus, R. Bergmann, M. Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Chemnitz University of Technology Institute for Machine Tools and Production Processes Germany

ISBN: (纸本)9783514007840

One approach in the area of material development Is the designing of materials properties by grain refinement. Methods of severe plastic deformation (SPD) can create ultrafine-grained or nanostructured metallic materials with outstanding properties. The material Is usually uniformly modified over the complete volume. The paper presents an innovative technological solution for efficient manufacturing of rod shaped specimen with locally different grain sizes. The resulting material properties In different regions of a graded aluminium billet are analyzed by hardness measuring and tension tests. The mechanical properties of processed standard aluminium specimen are Investigated. A method for the investigation of the properties In different layers with tensile tests Is presented. The mechanical parameters show the typical characteristics of coarse grained material in the core region, strain hardened material In the transition region and severely deformed material In the kneaded region of the specimen's outer layers. © 2011 Wiley-VCH Verlag GmbH & Co. KGaA. Weinheim.

关键词： Aluminum

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The Usage of Supercapacitors for Energy Storage Systems in the DC-Link of machine tools

The Usage of Supercapacitors for Energy Storage Systems in t...

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International Power Electronics and Motion Control Conference

作者： Reimund Neugebauer Stefan Winternheimer Artem Kolesnikov Mark Richter Fraunhofer Institute for Machine Tools and Forming Technology University of Applied Sciences of Saarland Chemnitz University of Technology Institute for Machine Tools and Production Processes

ISBN: (纸本)9781467319706

The development approach for an energy storage system with supercapacitors in the DC link of the drive unit in machine tools is focused on its optimal sizing in consideration of peak power reducing and energy efficiency improvement. The required change of parameters for the DC link voltage control was taken into account. The energy consumption of an electric drive with and without the energy storage system was investigated by means of experimental energy measurements and simulations of the energy consumption in Matlab/SimPowerSystem.

关键词： Efficiency Energy Storage Supercapacitor

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