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Micro-texture dependent temperature distribution of CVD diamond thick film cutting tools during turning of Ti-6Al-4V

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Procedia CIRP 2022年 108卷 483-488页

作者： E. Uhlmann D. Schröter E. Gärtner Technische Universität Berlin Institute for Machine Tools and Factory Management (IWF) Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 10587 Berlin Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

Machining titanium alloys such as Ti-6Al-4V results in a high thermomechanical load on cutting tools and consequently short tool lifes. With respect to a necessary reduction of the resulting cutting tool temperatures, ultrashort pulse (USP) laser fabricated micro-textured rake faces offer direct supply of cooling lubricant into the cutting zone and lead to a reduced heat induction. As a result, micro-textured CVD diamond thick film cutting tools are also capable of machining high-performance materials due to reduced contact temperatures. In the scope of the research, the resulting temperature distribution for micro-textured rake faces will be compared under both dry and wet process conditions. Measurements show a reduction of the resulting cutting tool temperatures of Δ ϑt = 27.9 % using micro-textured cutting tools compared to non-textured cutting tools. A validated simulation provides valuable information about the contact temperatures enabling a specific development of the micro-texture geometry. As a result, a reduction of the contact temperature between chip and rake face by Δ ϑ T = 24.7 % was possible.

关键词： diamond tool texture titanium turning temperature laser surface integrity

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Systematic design and implementation of a semantic assistance system for aero-engine design and manufacturing

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International Journal of Metadata, Semantics and Ontologies 2021年第2期15卷 87-103页

作者： Gogineni, Sonika Brünnhäußer, Jörg Lindow, Kai Konietzko, Erik Paul Stark, Rainer Nickel, Jonas Witte, Heiko Department of Virtual Product Creation Fraunhofer Institute for Production Systems and Design Technology Berlin Germany Chair Industrial Information Technology Technische Universität Berlin Berlin Germany Rolls-Royce Deutschland Blankenfelde-Mahlow Dahlewitz Eschenweg 11 Brandenburg15827 Germany

Data in organisations is often spread across various Information and Communication technology (ICT) systems, leading to redundancies, lack of overview and time wasted searching for information while carrying out daily activities. This paper focuses on addressing these problems for an aerospace company by using semantic technologies to design and develop an assistance system using existing infrastructure. In the aero-engine industry, complex data systems for design, configuration, manufacturing and service data are common. Additionally, unstructured data and information from numerous sources become available during the product’s life cycle. In this paper, a systematic approach is followed to design a system, which integrates data silos by using a common ontology. This paper highlights the problems being addressed, the approach selected to develop the system, along with the implementation of two use cases to support user activities in an aerospace company. Copyright © The Author(s) 2021. Published by Inderscience Publishers Ltd. This is an Open Access Article distributed under the CC BY-NC-ND license. (http://***/licenses/by-nc-nd/4.0/)

关键词： Knowledge management

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DEM-simulation of particle behaviour during cutting edge preparation of micro-milling tools by immersed tumbling 20

DEM-simulation of particle behaviour during cutting edge pre...

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20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020

作者： Uhlmann, E. Polte, M. Polte, J. Kuche, Y. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775176

The micro-milling process is widely used in industry for the manufacturing of complex geometries for a wide range of materials. To increase the tool life and cutting length the cutting edge preparation could be successfully established. Within preliminary investigations the immersed tumbling process was identified as the most promising process for cutting edge preparation of micro-milling tools. The process enables a reproducible cutting edge preparation with constant cutting edge radii as well as low chipping of the cutting edges. For a profound understanding of the preparation process and the process mechanisms further knowledge about the particle interactions with cutting tools as well as the particle flow mechanisms needs to be obtained. Therefore, the process simulation using discrete element methods (DEM) offers the possibility of an improved understanding of the process behaviour. In this investigation simulation studies about the cutting edge preparation of micro-milling tools using the immersed tumbling process will be presented. The DEM with the software ROCKY DEM from the company ESSS, Florianópolis, Brasil, was used and a process model was derived. The investigations show that the software can be successfully used for the visualisation of the immersed tumbling process and the flow mechanisms can be examined more closely. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Finite difference method

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Increased efficiency and accuracy in ultra-precision machining through adapted CAM software 20

Increased efficiency and accuracy in ultra-precision machini...

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20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020

作者： Uhlmann, E. Polte, J. Hein, C. Kuche, Y. Dörr, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775176

CAM software is widely used through the last 40 years for a broad field of applications. The networkability of machine tools and the digitally integrated production as an existing trend for the next years and exponentially increasing computing power enable direct data transfer between CAD/CAM software and machine tool. Increments ar Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Nanotechnology

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Development of monolithic ceramic milling tools for machining graphite 20

Development of monolithic ceramic milling tools for machinin...

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20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020

作者： Uhlmann, E. Polte, M. Polte, J. Kuche, Y. Hocke, T. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775176

Due to the international competition, continuous increases in productivity, product quality and reduction of production costs are required. Especially, the development of milling tools made of innovative cutting materials and application-specific tool geometries are in focus to overcome these challenges. Besides copper, graphite is the most important electrode material for electrical discharge machining (EDM). The machining of graphite leads to high tool wear due to a strong abrasive effect. Short tool life has a considerable influence on the economic efficiency of manufacturing processes. Currently, for the machining of graphite cost intensive diamond coated carbide tools are applied. In order to reduce machining costs, innovative cutting materials and dedicated manufacturing processes have to be applied. First results show a great potential of ceramics as tool material for machining graphite. The aim of this investigation is the characterisation and identification of novel ceramic cutting materials and the evaluation of an innovative tool micro-geometry especially designed for machining graphite. Therefore, the cutting material properties such as hardness, fracture toughness and wear resistance of four ceramic materials were investigated. Various hardness tests and particle blasting tests were carried out. Based on this investigations to manufacture the ceramic milling tools, a specific and innovative tool micro-geometry with defined angles was used. Thereby, a suitable cutting ceramic was identified, which represents a promising approach for an optimised machining of graphite. Copyright © Proceedings of the 20th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2020. All rights reserved.

关键词： Graphite

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Application of tool electrodes oxidised with humid and dry air during the electro-discharge drilling of MAR-M247 alloy 21

Application of tool electrodes oxidised with humid and dry a...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, M. Streckenbach, J. Camin, B. Chocholaty, O. Dinh, N.C. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany Institute for Materials Science and Technology Metallic Materials Technische Universität Berlin Germany Faculty of Mechanical Engineering Department of Material Science and Technology University of West Bohemia Czech Republic

ISBN: (纸本)9780995775190

The requirements and challenges of machining advanced materials in the field of aerospace, automotive and tool industry are increasing constantly. Due to their mechanical properties, cutting of high-strength materials such as superalloys is severely limited. Electro-discharge drilling can be used for the manufacturing of holes in hard to machine materials. Although electrical discharge machining (EDM) is successfully applied to the machining of holes in turbine blades, a lack of performance and challenges concerning the geometrical accuracy still remain. By applying inner flushing, the resulting electrically conductive debris is flushed through the lateral working gap, increasing the probability of arcs and short circuits. The resulting increased tool wear, conicity of the hole, limited hole depth and process instabilities are still challenging in electro-discharge drilling. In order to decrease the effects of the arcs and short circuits, a surface modification is applied to increase the electrical resistance of the lateral surface of the tool electrode. As a result, the mentioned impairments occur less frequently due to decreased occurrence of arcs and short circuits in the lateral working gap. For the present investigation copper tool electrodes were thermally oxidised in dry and humid air with different durations and used afterwards for electro-discharge drilling of MAR-M247. The tests were carried out on the machine tool AGIETRON Compact 1 from the company GF AgieCharmilles, Losone, Switzerland. Holes with a depth of t = 11 mm were drilled using various surface-modified tool electrodes with a diameter of d = 2 mm. Oxidation with dry air and a extended oxidation time resulted in a 18 % lower erosion duration, accompanied by an increase of the linear wear of the tool electrode Δle below 10 %. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Oxidation

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Influence of the weld pool geometry on solidification cracking in partial penetration high power laser beam welding 12

Influence of the weld pool geometry on solidification cracki...

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12th CIRP Conference on Photonic Technologies, LANE 2022

作者： Bakir, Nasim Üstündag, Ömer Gumenyuk, Andrey Rethmeier, Michael Unter den Eichen 87 Berlin12205 Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin10587 Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

Solidification cracking is still a serious problem in laser beam welding, especially in the welding of thick-walled plates. The influence of weld pool geometry on solidification cracking in partial penetration welding of thick plates is investigated within scope of this study. Therefore, a specific experimental setup of steel and quartz glass in butt configuration and on the side with high-speed camera were used to record the weld pool shape. In addition, the influence of laser inclination angle on the weld pool geometry and on solidification crack formation was investigated. The results show a bulge in the weld pool root, which is separated from an upper region by a necking region. This leads to a case where there are three different longitudinal region lengths with different solidification zones. This temporal sequence of solidification strongly promotes the formation of solidification cracks in the weld root. © 2022 The Authors. Published by Elsevier B.V.

关键词： Laser beam welding

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Assistance Method for the Application-Driven design of Machine Learning Algorithms 13

Assistance Method for the Application-Driven Design of Machi...

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13th International DAAAM Baltic Conference and 29th International Baltic Conference, BALTMATTRIB 2021

作者： Fono, Adalbert Thiele, Gregor Klein, Max Krüger, Jörg Fraunhofer Institute for Production Systems and Design Technology Berlin10587 Germany Department for Industrial Automation The Institute for Machine Tools and Factory Management Technical University of Berlin Berlin10587 Germany

Machine learning (ML) offers a lot of potential for applications in Industry 4.0. By applying ML many processes can be improved. Possible benefits in production are a higher accuracy, an early detection of failures, a better resource efficiency or improvements in quantity control. The use of ML in industrial production systems is currently not widespread. There are several reasons for this, among others the different expertise of data scientists and automation engineers. There are no specific tools to apply ML to industrial facilities neither guidelines for setting up, tuning and validating ML implementations. In this paper we present a taxonomy structure and according method which assist the design of ML architectures and the tuning of involved parameters. As this is a very huge and complex field, we concentrate on a ML algorithm for time series forecast, as this can be used in many industrial applications. There are multiple possibilities to approach this problem ranging from basic feed-forward neural networks to recurrent networks and (temporal) convolutional networks. These different approaches will be discussed and basic guidelines regarding the model selection will be *** introduced assistance method will be validated on a industrial dataset. © 2021 DAAAM International. All rights reserved.

关键词： Learning algorithms

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Automation of Life Data Analysis Processes 13

Automation of Life Data Analysis Processes

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13th International DAAAM Baltic Conference and 29th International Baltic Conference, BALTMATTRIB 2021

作者： Krämer, Jonathan Thiele, Gregor Johanni, Theresa Krüger, Jörg Department for Industrial automation The Institute for Machine Tools and Factory Management Technical University of Berlin Germany Department for Process automation and Robotics Fraunhofer Institute for Production Systems and Design Technology Germany

Life data analysis is an effective statistical process to gain information on the reliability of technical facilities. The Weibull analysis is a widely-used method for modeling the probabilities of different functional failures. For its application in modern manufacturing and maintenance processes, an automation of this analysis is expedient. An exemplary process of data collection and fitting of a parametric model with continuous time scale is analyzed in this article. Its automation with different statistic software tools is described and comparatively evaluated. With the ambition of minimizing manual effort in the process, a highly automated solution was developed in this research. We describe this self-implemented solution in "R" and justify that this procedure automatizes the process more than the examined commercial implementations. The here presented work proves to be a practical real-time assistance, right now applied in aircraft maintenance. © 2021 DAAAM International. All rights reserved.

关键词： Automation

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Improvement of Charpy impact toughness by using an AC magnet backing system for laser hybrid welding of thick S690QL steels 12

Improvement of Charpy impact toughness by using an AC magnet...

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12th CIRP Conference on Photonic Technologies, LANE 2022

作者： Üstündag, Ömer Bakir, Nasim Gumenyuk, Andrey Rethmeier, Michael Unter den Eichen 87 Berlin12205 Germany Fraunhofer Institute for Production Systems and Design Technology Pascalstraße 8-9 Berlin10587 Germany Institute of Machine Tools and Factory Management Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

The study deals with the influence of the heat input and the resulting cooling times on the microstructure and Charpy impact toughness of single-pass laser hybrid welded 20-mm thick high-strength steel S690QL. The main focus is on the change of the mechanical properties over the entire seam thickness. The cooling times were measured in-situ using a pyrometer and an optical fibre in three different depths of the seam where Charpy impact test specimens were also later taken. Thereby, three different heat inputs from 1.3 kJ/mm to 2 kJ/mm were investigated. Despite the observed decreased values of both t8/5-cooling time and the Charpy impact toughness in the root part of the seam, the required impact toughness of 38 J/cm2 could be reached in dependance on applied heat input, especially at the heat input of 1.6 kJ/mm. © 2022 The Authors. Published by Elsevier B.V.

关键词： High strength steel

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