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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Uhlmann, E. Perfilov, I. Yabroudi, S. Schweitzer, L. Polte, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775121

For the electro-discharge drilling of micro-holes with small diameters D the production and the guidance of the tool electrode are most challenging. For holes with diameters D ≤ 50 μm the required electrodes have to be produced by electro-discharge dressing, which leads to a considerable increase in the production effort as well as the production costs. The small diameters 5 μm ≤ d ≤ 15 μm as well as the good electrical conductivity κ of carbon fibres make it possible to use a single carbon fibre as an electrode for electro-discharge drilling. The paper presents the results of experiments with non-rotating single carbon fibres as tool electrodes for electro-discharge drilling. The process parameters were optimised for the machining of through-holes in a workpiece made of stainless steel 1.4310 with a thickness h = 20 μm and h = 50 μm respectively. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Carbon fibers

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Diamond burnishing for mould and die industry 18

Diamond burnishing for mould and die industry

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

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

ISBN: (纸本)9780995775121

关键词： Surface roughness

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Laser surface hardening of engine camshaft cams

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Materials Today: Proceedings 2020年 30卷 478-482页

作者： Irena Lasota Vladimir Protsenko Alexey Matyushkin Mikhail Kuznetsov Sergey Gook Peter the Great St. Petersburg Polytechnic University St. Petersburg Russian Federation St. Petersburg State Marine Technical University St. Petersburg Russian Federation RWS GmbH D-76131 Karlsruhe Germany Fraunhofer Institute for Production System and Design Technology IPK Berlin Germany

The publication describes research into the laser hardening process of the camshaft cams surface. Samples of camshaft cams made of structural bearing steel were hardened using a powerful fiber laser LS-15. The effect of altering the laser surface hardening process parameters on the microstructure and microhardness of the surface was investigated. Also, the influence of low-temperature tempering after laser surface hardening was shown.

关键词： Laser surface hardening Metal treatment Microstructure Microhardness Camshaft

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Wear behaviour of HIPIMS coated micro-milling tools with cutting edge preparation for machining steel moulds 18

Wear behaviour of HIPIMS coated micro-milling tools with cut...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

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

ISBN: (纸本)9780995775121

Micro-milling is an appropriate process for the industrial production of precision parts in the mould and die industry. Decisive for a long tool life is the wear resistance, which can be improved by cutting edge preparation technologies and tool coatings. Especially the improvement of the coating technology with the high power impulse magnetron sputtering (HIPIMS) provides improved tool wear behaviour and longer path length lc. Further studies compare two different HIPIMS-coatings of micro-milling tools for machining the mould steel X13NiMnCuAl4-2-1-1. Furthermore, the tool wear could be reduced due to cutting edge preparation using immersed tumbling process. In consequence of the increased cutting edge radii rβ the measured active forces Fa increased slightly. Best results were achieved for micro-milling tools with cutting edge preparation and AlTiN coating. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Coatings

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On the Selection and Application of a Convenient Energy Management Software for Industrial Purposes

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IOP Conference Series: Materials Science and Engineering 2021年第1期1140卷

作者： Larissa Wurster Gregor Thiele Clemens Briese Jörg Krüger Plant Development Infrastructure / Assembly Trucks (TG/MAD) Daimler Truck AG Department for Process automation and Robotics Fraunhofer Institute for Production Systems and Design Technology Department for Machine Vision Fraunhofer Institute for Production Systems and Design Technology Department for Industrial automation at the Institute for Machine Tools and Factory Management Technical University of Berlin

The profitability of companies, especially in Germany, is affected by rising energy prices and increasingly stringent energy legislation. Certification according to ISO 50.001, an international standard for energy management systems, can help to meet legal requirements and increase energy efficiency. This article offers assistance in the form of a methodology that provides a structure for the selection process of an energy management system (EnMS). Considering properties of the individual company, it helps to identify an appropriate software solution. It is applied to a globally operating metalworking company in an example study. Furthermore, the measurement infrastructure in particular is a basic requirement that should not be overlooked in addition to the process of choosing an appropriate software solution. In this context, suitable metering points or criteria must be defined as well as sufficient attention paid to the anticipated costs for acquiring and integrating new measuring transducer and energy meters. The type and number of relevant measuring points must be considered in particular. Discussing these aspects, this article facilitates the process of planning and implementing an energy monitoring.

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Laser welding of Inconel 718 nickel-based alloy layer-by-layer products

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Materials Today: Proceedings 2020年 30卷 473-477页

作者： Alexander Voropaev Maxim Stramko Alexander Sorokin Ivan Logachev Mikhail Kuznetsov Sergey Gook St. Petersburg State Marine Technical University St. Petersburg Russian Federation Joint Stock Company «Kompozit» Russian Federation Peter the Great St. Petersburg Polytechnic University St. Petersburg Russian Federation Fraunhofer Institute for Production System and Design Technology IPK Berlin Germany

This article describes the results of the study of optimal conditions for welding alloy products - Inconel 718, made with the method of layered laser growing (SLM). The results of the study of the influence of linear energy, rigid fixation of parts during welding and heat treatment on microhardness, welding deformation and the microstructure of the welded joint are presented.

关键词： Laser welding Inconel 718 SLM Heat-treatment Microstructure

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Pocket milling of composite fibre-reinforced polymer using industrial robot

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Procedia CIRP 2019年 85卷 183-188页

作者： Ever Grisol de Melo Tiago Borsoi Klein Sascha Reinkober Jefferson de Oliveira Gomes Eckart Uhlmann Department of Mechanical Engineering Aeronautics Institute of Technology (ITA) Marechal Eduardo Gomes 50 São José dos Campos 12228-900 Brazil Fraunhofer Institute for Production Systems and Design Technology (IPK) Pascalstraße 8-9 Berlin 10587 Germany

In the recent decades, aerospace and automotive industry are replacing metal materials by carbon fibre-reinforced polymer (CFRP). The mechanical properties of CFRP materials are very attractive due to high mechanical strength and low weight. However, there are technological challenges in the machining process for this type of material. The anisotropy and inhomogeneity of the CFRP cause high wear of the cutting tool, spalling, delamination, fuzzing, fibre pull-out, matrix cracking, thermal degradation and resulting in poor quality of the part. In addition, the requirement for processes that are more flexible within a larger work area makes the use of industrial robot (IR) a promising alternative. The present work evaluated the performance of the IR regarding motion accuracy, which influences machining conditions of composites. The trimming in a pocket milling was carried out using the factional replication of the 3k factorial design, with three levels and three factors. The tool geometry, feed rate fz and spindle speed n were selected as input parameters. In order to evaluate the robotic machining performance, resultant cutting force Fr, surface and dimensional quality were selected as output parameters to be assessed. After obtaining the force results, equations were generated for each cutting tools and Response Surface Methodology (RSM) was applied. The results show that the use of IR is a promising alternative for the CFRP machining of large aeronautical components.

关键词： carbon-fibre-reinforced polymer (CFRP) industrial robot (IR) machining process high speed cutting (HSC)

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Smart Maintenance – dynamic model-based instructions for service operations

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Procedia CIRP 2019年 81卷 1417-1422页

作者： Eckart Uhlmann David Franke Eckhard Hohwieler Fraunhofer-Institute for Production Systems an Design Technology (IPK) Pascalstraße 8-9 Berlin 10587 Germany Technische Universität Berlin – Institute for Machine Tools and Factory Management (IWF) Pascalstraße 8-9 Berlin 10587 Germany

Due to the increased complexity of machines and plants service technicians have to be more trained to be able to maintain them. In many service operations it is still common to use simple service manuals like checklists. With the strong growth of the information and communication technology it is possible to create interactive and context-sensitive tools to support service technicians during operations. One problem is that these tasks are always in change by new knowledge. To solve this issue a model-based engine is being developed to dynamically generate instruction-tools for service operations for direct machine communication.

关键词： service assistance system human-machine-interaction maintenance model-based

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Automation of Life Data Analysis Processes

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IOP Conference Series: Materials Science and Engineering 2021年第1期1140卷

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

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.

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Manufacturing and replication of sub-10 μm micro-bowls for biomedical sensor systems 18

Manufacturing and replication of sub-10 μm micro-bowls for ...

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18th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2018

作者： Uhlmann, E. Hein, C. Polte, M. Polte, J. Dähne, L. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Surflay Nanotec GmbH Germany

ISBN: (纸本)9780995775121

The technical implementation of a novel biosensor for the highly parallelized screening of biochemical binding reactions depends on the manufacturing of an array of micro-bowls with a diameter dB ≤ 10 μm with an aspect ratio ar ≥ 1. Since the operating principle of the biosensor is based on the stimulation of stationary optical waves in micro-spheres, micro-bowls for the immobilisation of these spheres in a microfluidic environment are necessary. Due to this operating principle, the micro-bowls need to separate the spheres from the fluid flow and ensure the careful adherence of single spheres, coincidently. Moreover, the pathway for the optical accessibility of the micro spheres should be unrestricted. This work presents a process chain for the manufacturing of microfluidic chips with an array of n ≥ 1,000 micro-spheres by ultra-precision milling of mold inserts, the replication by precision injection molding as well as experimental trial results. With regard to manufacturing of the mold inserts, the uniform and burr free ultraprecision milling of large aspect ratio micro posts was investigated within a parametric study. Furthermore, the replication of the micro-bowls was examined by taking the consistent replication of the entire bowl array, the adverse formation of fillets, and the replication of surfaces with optical functions into special account. By the analysis of the microfluidic and optical properties of the replicated structures, the correlation between mold manufacturing, replication, and operating conditions can be performed. © 2018 CURRAN-CONFERENCE. All rights reserved.

关键词： Biosensor Injection molding Micro-bowl Ultraprecision milling

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