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Structure and Validation of a Kinematic Surface Simulation Model for the ultrashort-pulse Direct-Laser-Writing Process

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Procedia CIRP 2025年 133卷 227-232页

作者： Fabian Wieland Eric Gärtner Sebastian Wieland Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Functional Surfaces and Micromanufacturing Reichenhainer Str. 88 Chemnitz 09126 Germany

This paper presents the development and validation of a kinematic surface simulation model for the prediction of ultrashort-pulsed laser structured surfaces. The simulation is based on an existing kinematic simulation model for short-pulsed laser structuring and utilizes the stepwise Boolean intersection of a machined and digitized single point ablation with the workpiece to reproduce the microstructuring process. The existing short-pulse simulation model was extended by newly integrated description models to allow a more detailed representation of within the process changing influences, e.g. the surface fine-structure to enable a multi-layer processing. In addition, a reorganization of the simulation algorithm resulted in a general improvement of the run time and a resolution-independence. Based on the kinematic simulation principle, the manufacturing process for a wide range of material-machine combinations in the field of laser structuring can be described. The model enables a time-efficient, nanometer-resolved prediction of representative surfaces with a size of up to several square millimeters. Furthermore, complex influences such as material- and temperature-related properties do not need to be considered separately, as they are taken into account by the machined and digitized single point ablation. Compared to artificial intelligence approaches and numerical or multiphysical simulations, the need for preliminary studies is very low. Depending on the chosen laser machining parameters the simulation can reproduce the surface textures macro- and microstructure.

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Integrating Hybrid Physics-Data Approaches for Enhanced Cutting Force Modeling in Digital Twins of Helical End Mills

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Procedia CIRP 2025年 133卷 358-363页

作者： Yuan Jing Guanchen Gong Albrecht Hänel Steffen Ihlenfeldt Fraunhofer Insitute for Machine Tools and Forming Technology IWU Chemnitz Germany Chair of Machine Tools Development and Adaptive Controls Institute fo Mechatronic Engineering Technische Universität Dresden Dresden Germany

Industry 4.0 has significantly improved data efficiency by leveraging key technologies such as the Internet of Things and machine Learning. Among these key technologies, digital twins stand out by offering a promising approach to intelligently utilize this data. In the virtual representation of a physical asset, data reflects the conditions of the physical entity, while models simulate and predict its behavior. In this paper, a hybrid cutting force model is proposed for digital twins of helical end mills, focusing on cutting force analysis during the utilization phase of the machining process. This model combines a fairly mature physical process modelling approach with a data-driven method, specifically a neural network trained on real process data, to address the limitations inherent in their respective applications. The physics-based model provides meaningful constraints on the neural network’s training, ensuring reliable cutting force prediction, particularly in scenarios with limited process data availability. The cutter’s profile, generated by the geometric model, and the cutter-workpiece engagement maps, derived from the virtual machining model, together serve as inputs for the hybrid cutting force model.

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Virtual sensor for monitoring the geometric and kinematic accuracy of machine tools 19

Virtual sensor for monitoring the geometric and kinematic ac...

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19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Doerrer, Felix Otto, Andreas Kolouch, Martin Rentzsch, Hendrik Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

The performance of machine tools depends on their working accuracy. The paper presents a new approach for in-process monitoring the geometric and kinematic accuracy of a machine tools. This approach utilizes a virtual sensor for capturing displacements at the tool center point (TCP). The virtual sensor is set up by using a data-driven approach based on extended transmissibility functions. The input data for monitoring are the NC internal data. The transmissibility functions are established via standard experimental procedures such as double ball bar (DBB) tests tests and estimation of frequency response functions (FRF). The data from the virtual sensor can be used for process monitoring and troubleshooting when launching a new process. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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New gentle extraction method of hemp bast strips for use as bio-based reinforcing fibers in highly loaded fiber composites

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Procedia CIRP 2024年 125卷 178-183页

作者： Steffen Ihlenfeldt Jens Müller Christoph Peukert Ludwig Rogall TUD Dresden University of Technology Chair of Machine Tools Development and Adaptive Controls (LWM) Dresden 01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz 09126 Germany

Nowadays, fiber composites are among the most important construction materials in lightweight design. Increasingly, attempts are being made to replace fossil raw materials with bio-based materials in order to improve their recyclability and reduce greenhouse gas emissions. While processes suitable for industrial use already exist for the production of biopolymers as matrix materials, there is still a considerable need for research in the production of bio-based reinforcing fibers. For hemp bast strips (HBS), promising utilization options arise due to very good mechanical properties. However, current processes for extracting such raw materials from bast fiber plants result in damage to the fiber structure because they use biochemical decomposition processes and/or squeeze and crush large disordered amounts of stalk along their entire length. This strongly reduces the application potential of the raw materials. A newly developed principle extracts the HBS with minimal impact by dividing single hemp stalks only at one end and then isolating them from the wood core by pulling on the resulting wood fragments. In this manner, the fiber structure and the good mechanical properties are largely retained and the HBS obtained can be stored in parallel alignment for further processing with little effort.

关键词： natural fiber composites hemp decortication mechanical properties industrial application

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Case Study of Robot Machining at Different Working Space Locations

Case Study of Robot Machining at Different Working Space Loc...

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MECHATRONIKA International Symposium

作者： Mikuláš Szabari Jan Berhold Jan Vetiška František Bradáč Michal Holub Martin Dix Institute of Production Machines Systems and Robotics Brno University of Technology Brno Czech Republic Cutting Technology Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany

ISBN: (数字)9798350394900

ISBN: (纸本)9798350394917

Machining, 3d printing and robot welding require a minimum difference between simulated and real position of robot (TCP) to facilitate high quality surface finish and fulfil dimension and form tolerance. The solution is the absolute robot calibration, which increases positional accuracy. In this paper, a calibrated direct-measuring robot is used to machine the sample part. In the experiment, the sample part is positioned at different location and machined by different machining processes. Then the produced part is measured on a coordinate measuring machine (CMM). The quality of the surface finish, dimensions and geometric tolerances are evaluated. This experiment showed the effect of calibration on the machining process. Based on the obtained results, further activities will be directed in the field of increasing the geometric accuracy of industrial robots.

关键词： Drilling Accuracy Coordinate measuring machines Service robots Robot kinematics Machining Kinematics Surface finishing Robots Surface treatment

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Methods for the environmental and economic assessment in early product design – a case study-based overview for wind turbines in urban areas

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Procedia CIRP 2024年 122卷 789-794页

作者： Martin Zumpe Maximilian Stange Ahmet Burak Ertem Marian Süße Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The assessment of environmental impacts has become an inevitable necessity for many manufacturing companies – not only from a mere retrospective viewpoint but also for product design decisions. At the same time, economic feasibility must be constantly considered throughout all product design phases. For both dimensions, many different decision-support methods exist. However, there is a lack of combined assessment methods especially in early product design phases, when product characteristics, manufacturing technologies and corresponding data are still uncertain. The paper provides an overview and qualitative evaluation of different methods for economic and ecological assessment in product design stages. Based on this, a generalized procedure for combined economic and ecological decision-making during product design is derived, highlighting possible coping mechanisms for uncertain or insufficient data. Both, the evaluation of available assessment methods as well as the derived procedure are transferred to the specific requirements of wind turbines in urban areas. As a result, open research aspects and the next steps for method development are derived.

关键词： Eco-design methodology LCA Evaluation Environment Wind Turbines

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Combining material flow simulation and optimization for sustainable manufacturing – application in automotive paint shops

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Procedia CIRP 2024年 122卷 659-664页

作者： Marian Süße Xinyi Xie Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

The necessity for sophisticated decision support in industrial manufacturing has been described manifoldly and simulation approaches as well as optimization methods are continuously developed. This can be especially promising when it comes to decision-making with multidimensional requirements of economic and ecological efficiency. However, due to the required expert knowledge, there is still a gap between theoretically applicable and industrially applied methods. The paper therefore presents results of two use cases as part of the European project ECOFACT where different approaches for the combination of simulation and (heuristic) optimization were applied with industry partners. An overview of recent works and systematic literature reviews of sustainable manufacturing and the approaches for combining simulation and optimization is given. Correspondingly, the investigated use cases of automobile paint shops refer to the reduction of environmental impacts by optimized heating processes and an improved batching process to minimize paint waste. In the first case, setup times for heating color pools and ovens were shifted to avoid load peaks in a calculation time of less than one minute. In the second use case batch size was increased by around 25%.

关键词： Sustainable manufacturing Energy Simulation Optimization

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A survey on smart product-service systems in manufacturing

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Procedia CIRP 2023年 120卷 1504-1509页

作者： Anton Mauersberger Mohaned Alaluss Antonia Beyer Kilian Armin Nölscher Alexander Rauscher Heiner Reinhardt Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

The advancing digitization affects product design and manufacturing. Companies focus on product-service systems (PSS) to improve customer satisfaction and loyalty. However, these PSS become increasingly complex as digital technologies are incorporated and cross-company collaboration and manufacturing is facilitated. In essence, we can observe a transition from conventional PSS to smart PSS, where the opportunities of digitization are effectively utilized and synergies between multiple stakeholders are fostered. Here, we present an analysis and classification of smart PSS considering aspects of business modeling, composition, design, quality and sustainability.

关键词： Smart PSS Smart service Smart technologies Product-service system Remote service Development Innovation management Production Modular design Decision making

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A survey on sustainability approaches in manufacturing 30

A survey on sustainability approaches in manufacturing

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30th CIRP Life Cycle Engineering Conference, LCE 2023

作者： Prell, Bastian Reinhardt, Heiner Mauersberger, Anton Rauscher, Alexander Reiff-Stephan, Jörg Ihlenfeldt, Steffen Technical University of Applied Sciences Wildau Hochschulring 1 Wildau15745 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Awareness about climate change has led to policies and regulations but also customer preferences favoring sustainable production. Thus, producing businesses are confronted by this, as they consume a large share of resources. Therefore, when producing, additional dimensions beyond commercial feasibility ought to be considered. Here, literature on sustainability from the field of engineering science is systematically searched and analyzed for approaches leading to actual recommendations for action. Hence, this bottom-up approach, incorporating the production engineers' point of view, represents an inside view of how the topic of sustainability has arrived at production companies. The focus on commercial feasibility ensures high relevance to practice, as production needs to become both sustainable and competitive. Even though exemplary collections of different approaches addressing the topic of sustainability in production can be found in literature, novelty is provided by the structured manner literature was collected and the special focus on approaches leading to practice-relevant recommendations for action. Thus, a comprehensive overview of approaches applicable to the manufacturing domain is presented. © 2023 The Authors. Published by Elsevier B.V.

关键词： Sustainable development

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Identifying efficiency and flexibility measures for energy-oriented factory management 29

Identifying efficiency and flexibility measures for energy-o...

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29th CIRP Conference on Life Cycle Engineering, LCE 2022

作者： Münnich, Marc Rein, David Reinhardt, Heiner Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

Recent efforts in climate politics increase the ecological pressure of manufacturing companies in terms of intelligent and efficient usage of resources during operations. Rising energy prices lead to further economic pressure. Especially companies with a high share of energy cost on total costs are forced to continuously improve processes regarding the energy usage. Existing guidelines and methodologies are usually concerned with either of the two dimensions energy efficiency (EnEff), or energy flexibility (EnFlex). While EnEff addresses the reduction of the energy consumption for a defined manufacturing output, EnFlex addresses the advantageous shift, increase, and decrease of energy demand. Although both dimensions address the total reduction of cost, they are usually considered separately in literature. Here, we examine both dimensions while focusing on the provision and usage of electric energy due to its manifold conversion and usability opportunities in factory processes. Therefore, we developed an overview of measures of both dimensions as well as their application characteristics within the factory. To identify EnEff and EnFlex measures, a practicable methodology is introduced. This aims to enable especially companies with few experiences in EnEff and EnFlex measure application to improve energy aware operations. We illustrate our examination by means of an industrial application example. © 2022 Elsevier B.V.. All rights reserved.

关键词： Energy efficiency

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