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Implementation of a handling system for using carbon fibres as tool electrodes in micro-ED drilling 23

Implementation of a handling system for using carbon fibres ...

引用

23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

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

ISBN: (纸本)9781998999132

Electrical discharge machining (EDM) processes represent an established process for the machining of complex geometries in hard to cut and electrically conductive materials. Nevertheless, micro-electrical discharge drilling still poses the challenge of machining holes with diameters dh ≤ 50 μm. The preparation of even smaller pin tool electrodes demands a great amount of non-productive time, which often involves the use of additional electrical discharge dressing processes for its manufacturing. A possible solution is the use of single carbon fibres with diameters 5 μm ≤ del ≤ 10 μm as tool electrodes. The use of these single fibres comprises a challenge due to their geometrical and mechanical properties, e.g. diameter and brittleness. To overcome this challenge, an existing handling system for carbon fibres was re-designed considering the obstacles that arose with the use of previous versions of such systems. This includes the replacement of the liquid rubber coating of the movable clamping jaw in order to use foam rubber to achieve a better distribution of the clamping force that establishes the electrical contact between the carbon fibre and a conducting copper plate. The geometry of the borosilicate glass micro-pipette was redesigned to ensure an accurate positioning of the carbon fibre due to its inner tip diameter 15 μm ≤ dt ≤ 35 μm and to enable the use of fibre electrodes with a length of 15 mm ≤ le ≤ 25 mm. This hinders the deflection of the fibre tip during the machining process and enables the precise guidance of the fibre. Furthermore, the developed handling system was implemented for performing single discharge experiments, in which parameters such as open circuit voltage, charge current and discharge capacity were varied in order to determine their influence on the material removal process. © 2023 Euspen Headquarters.

关键词： Rubber

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Characterisation and investigation of ion-implanted boron-doped single crystal diamonds as temperature sensor for ultra-precision machining 23

Characterisation and investigation of ion-implanted boron-do...

引用

23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Polte, M. Hocke, T. Thißen, K. 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)9781998999132

Ultra-precision machining is a crucial manufacturing process for the production of optical components in automotive, medical and aerospace industry and enables high dimensional accuracies and low surface roughness values. Dedicated single crystal diamond tools enable the manufacturing of optical and functional surfaces such as mirrors or lenses. Despite the high mechanical hardness, temperature induced chemical wear of the diamond tools occures during the process. To characterise und interpret the wear behaviour of diamond tools, the cutting temperature needs to be analysed. At state of the art, there are no precise methods available for analysing temperatures in the cutting zone of a single crystal diamond tool in order to identify the wear behaviour online during the process. Therefore, a dedicated measurement system based on boron-doped CVD single crystal diamonds as temperature sensor was developed. The electrosensory features of the fully boron-doped diamonds enable a direct temperature measurement in the cutting zone. To enable high sensitive temperature measurements, ion-implantation was used for partial and specific boron-doping close to the cutting edge of single crystal diamonds. To fundamentally evaluate the quality of the doping and contacting structures as well as the general process of the ion-implantation three different doping structures were investigated using single crystal diamond blanks prior doping the cutting tools. For this purpose, the boron-doped structures were optically characterised and the correlations between the resistances and the temperatures were evaluated as a function of different doping-levels and doping-lengths. First results show the successful application of the ion-implantation for boron-doping of single crystal diamonds. It could be proven that the selected boron-levels as well as boron-lengths lead to different initial conditions of the analysed specimens. Dedicated ionimplantation of single crystal diamond tools represents

关键词： Surface roughness

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Wear mechanism of single crystal diamonds in ultra-precision cutting of graphite for air bearing applications 23

Wear mechanism of single crystal diamonds in ultra-precision...

引用

23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

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

ISBN: (纸本)9781998999132

In order to meet the continuously increasing function-determining requirements of complex precision components, advances in machine tool components are necessary in addition to technological developments. In this context, motorized spindles in particular show great potential for enabling further increases in accuracy. To achieve high stiffness and damping behaviour of spindle systems, aerostatic bearings made of graphite with bearing gaps Sg S ≤ 1 μm are necessary. Regarding the state of the art, uncoated tungsten carbide tools, diamond coated carbide tools and thick film chemical vapour deposition (CVD) diamonds are used for cutting graphite materials. Cutting with these tools leads to asymmetric breakout behaviour of the graphite grains as well as high tool wear during machining, resulting in insufficient shape accuracies and surface qualities. A promising approach to overcome the current challenges for aerostatic bearing components made of graphite is the use of single crystal diamonds (SCD) with characteristic low rounded cutting edge radii rß ≤ 20 nm as well as cutting-edge waviness wa ≤ 200 nm. Besides the material-specific properties of the SCD, tool wear occurs during the cutting of graphite. For this purpose, the abrasive wear mechanism and surface attrition of SCD were analysed concerning specific blasting tests with defined time intervals of 60 s ≤ tb ≤ 3,000 s and different process conditions. Furthermore, two types of graphite granulate with grain sizes in a range of 200 μm ≤ gs ≤ 400 μm were used. First results show a dimensional loss of material on the investigated specimens made of SCD depending on the process conditions, whereby an influence of the surface attrition could be proven. © 2023 Euspen Headquarters.

关键词： Graphite

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DEM simulation of centrifugal disc finishing using smoothed particle hydrodynamics 23

DEM simulation of centrifugal disc finishing using smoothed ...

引用

23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Uhlmann, E. Polte, J. Kuche, Y. Hocke, T. 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)9781998999132

Centrifugal disc finishing is a widely used technology forserial post-processing of small components made of various materials. During the process, the workpieces are completely surrounded by dry or moist abrasive media, making it difficult to obtain precise information about particle contacts or the movement of the workpieces. Numerical analysis through the discrete element method (DEM) has the potential to improve the understanding of the process, but the accurate representation of moist particles with varying contact conditions remains a challenge. This paper compares different contact models using the ROCKY DEM software, including the liquid-bridge model and the smoothed particle hydrodynamics (SPH) model. The analysis indicates that, compared to other models, SPH demonstrates clear advantages in representing process water flow and is better suited for cases with higher water content in the medium. © 2023 Euspen Headquarters.

关键词： Finite difference method

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DEM Simulation of Abrasive Brushing Processes on Additively Manufactured Workpieces 20

DEM Simulation of Abrasive Brushing Processes on Additively ...

引用

20th CIRP Conference on Modeling of Machining Operations in Mons, CIRP CMMO 2025

作者： Hoyer, Anton Uhlmann, Eckart Technische Universität Berlin Pascalstr. 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstr. 8-9 Berlin10587 Germany

Brushing with bonded abrasives is a finishing process mainly used for deburring, edge rounding, and surface roughness reduction. The brushing tools consist of flexible polymer filaments embedded with abrasive grains, allowing them to adapt to complex workpiece shapes. However, interactions between filaments lead to complex motion, chipping, and wear behaviors, making it difficult to predict work results. The discrete element method (DEM) has been shown to be effective in simulating process forces, contact areas, and filament interactions on flat workpieces. Consequently, this article focuses on processing geometrically complex workpieces, particularly additively manufactured turbine fan blades (Ni-Cr-Co), using round brushes with bonded silicon carbide. First, a vectorized iterative method is introduced to generate artificial filament patterns, enhancing DEM simulation accuracy compared to state-of-the-art filament pattern models. Subsequently, dry brushing experiments are carried out on a fan blade feature demonstrator, aiming to achieve homogeneous roughness reduction. The qualitative analysis of the contact surface suggests that results from DEM simulations can reduce the need for costly technological investigations and prototypes. © 2025 The Author(s).

关键词： Nickel alloys

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Developing a Framework for Sustainable Education in a production Engineering Study Program 19th

Developing a Framework for Sustainable Education in a Produc...

引用

19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Mintchev, Maxim Eingartner, Valentin Muschard, Bernd Oertwig, Nicole Technische Universität Berlin Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

ISBN: (纸本)9783031774287

Given the current challenges faced by the world regarding climate change and the goals outlined by the United Nations in their Agenda 2030 for Sustainable Development, sustainability is increasingly gaining importance in education and industry. To be able to tackle the challenges of responsible consumption and production, societies need to prepare highly skilled and responsibly thinking engineers, who are fit for the market while also contributing actively to the transformative change towards sustainable economies and societies. The international master program Global production Engineering (GPE) at Technische Universität Berlin aims to impart knowledge on production, engineering, and management with a major focus on sustainability. In this paper, policies of universities locally and worldwide are reviewed and lecturers of GPE are surveyed to determine which sustainability topics and approaches are integrated in their lectures and in the curriculum. From this, a framework for competence building for sustainable development in the economy is developed. The program is then reviewed and found to be teaching some of the core competencies outlined by the Education for Sustainable Development, albeit with a clear potential for improvement. To address this, corrective measures are proposed. © The Author(s) 2025.

关键词： Sustainable development goals

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Planning and Control of Value Creation Networks in Timber Construction 19th

Planning and Control of Value Creation Networks in Timber Co...

引用

19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Orozco, Sebastian Oertwig, Nicole Feldhaus, Annika Eingarnter, Valentin Mintchev, Maxim Kohl, Holger Technische Universität Berlin Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

ISBN: (纸本)9783031774287

Almost 40 percent of the global carbon emissions are caused by the construction and building sector. Additionally, the production of traditional building materials like concrete and steel requires a large amount of energy. The demand for residential buildings is increasing none the less and can potentially be met by utilizing more sustainable materials like timber in construction. However, timber construction is still connected to a rather manual value creation chain and analog information transfer. To make the process more time- and energy efficient, this paper proposes a framework for the value creation system of urban timber construction from the forest to the city. The three-leveled framework, based on the principles of Industry 4.0, connects the urban development planning with the vertical networking of digital technologies and the horizontal networking in the value chain. The framework is implemented to a dashboard using Microsoft Power BI to demonstrate the close relations of the layers. © The Author(s) 2025.

关键词： Digital transformation Timber construction Value creation network

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technology Radar for a Sustainable Biological Transformation in the Manufacturing Industry 19th

Technology Radar for a Sustainable Biological Transformation...

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19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Mügge, Janine Berkhahn, Magda Knauf, Tobias Stark, Rainer Faßbender, Lynn Lange, Annika Riedelsheimer, Theresa Lindow, Kai Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

ISBN: (纸本)9783031774287

Bio-inspired, bio-integrated, bio-intelligent product and production systems are new research approaches aimed at achieving sustainability in manufacturing. For the industrial application of new technological solutions, it is crucial to convey their added value from not only an economic but also an environmental perspective. The evaluation of their technological readiness plays an important role in implementation. This paper presents a technology radar developed and evaluated within German research project BioFusion 4.0 involving 13 industry and research partners. The paper outlines the development approach and its application by means of three technological examples. The technologies are categorized and assessed using four significant attributes of an effective biological transformation: (1) the mode of action (bio-inspiration, bio-integration, and bio-interaction);(2) the transformative character and (3), the technology—and (4) Sustainability Readiness Level. The technology radar comprises a step-by-step procedure to assess a technology by each criterion to enable different stakeholders, such as production planners or product developers to evaluate and identify suitable technologies according to their needs and business strategy. The application of the technology radar is demonstrated on the exemplary technologies of a digital twin with integrated life-cycle assessment, situation awareness monitor for networked production systems and bio-based 3D printing. © The Author(s) 2025.

关键词： Biotic

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Corporate Climate Protection Measures to Improve the Carbon Footprint in production: A Systematic Development of a Toolbox with Climate Protection Actions for the Reduction of Greenhouse Gas Emissions in Small and Medium-Sized Enterprises 19th

Corporate Climate Protection Measures to Improve the Carbon ...

引用

19th Global Conference on Sustainable Manufacturing, GCSM 2023

作者： Budde, Felix Kohl, Holger Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstraße 8-9 Berlin10587 Germany Technische Universität Berlin Pascalstraße 8-9 Berlin10587 Germany

ISBN: (纸本)9783031774287

Individual climate protection measures are already being successfully implemented by many companies. But often, there is a lack of comprehensive information for selecting and implementing the right measures that fit the individual company’s emissions profile. This paper presents the systematic development of a toolbox of climate protection actions for small and medium-sized enterprises in order to reduce greenhouse gas emissions. The development process followed a four-step methodological approach: conducting intensive research on climate protection measures in applied and practical literature, reducing and grouping the measures into their corresponding emission categories, structuring and categorizing the measures into specific types of areas, and providing detailed profiles and descriptions of each measure. The resulting list of climate protection actions follows underlying basic principles (i.e. improvement of the emission factor, reduction of emission-generating activities and behavioral changes) which allow an individual derivation of measures. In its final version, the toolbox provides small and medium-sized enterprises with a comprehensive and accessible resource for identifying and implementing effective climate protection actions according to their emissions profile. © The Author(s) 2025.

关键词： Greenhouse gas emissions

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Planning of Time-Efficient Trajectories for Mobile Robots with Differential-Drives

Planning of Time-Efficient Trajectories for Mobile Robots wi...

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International Conference on Emerging Technologies and Factory Automation (ETFA)

作者： Philipp Lelidis Axel Vick Production Machinery and Equipment Management Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany Process Automation and Robotics Fraunhofer Institute for Production Systems and Design Technology IPK Berlin Germany

ISBN: (数字)9798350361230

ISBN: (纸本)9798350361247

To effectively utilize the capacities of the production facilities, flexible and fast transport, and manipulation technology is essential. Current path planning methods use simple paths without exploiting the physical limitations of mobile robots. This paper deals with the time-efficient kinematic planning of path and velocity trajectories for autonomous mobile robots equipped with a differential-drive, used to load and unload machine tools. For a close parking position next to the machine tools, the mobile robot must approach practically straight without the necessity of turning at the end. After a brief definition of the kinematics of a mobile robot with nonholonomic constraints, a Bezier-curve is combined with multiple jerk-limited velocity trajectories considering the initial and final state as well as the physical limitations. For a time-efficient acceleration and deceleration the maximum acceleration of the mobile robot is used and differentiated into the radial and tangential acceleration. This allows a quickly reached close parking pose next to a machine tool. The algorithm is tested with simulations in RVIZ in combination with Gazebo and ROS2 as well as with the real mobile robot Tend-o-Bot.

关键词： Kinematics Turning production facilities Trajectory Planning Machine tools Mobile robots Manufacturing automation Load modeling Autonomous robots

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