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16th CIRP Conference on Intelligent Computation in Manufacturing Engineering, CIRP ICME 2022

作者： Rytir, Michal Rönnecke, Jonas Hänel, Albrecht Kolar, Petr Ihlenfeldt, Steffen Czech Technical University in Prague Czech Institute of Informatics Robotics and Cybernetics Department of Industrial Production and Automation Jugoslávských partyzánu 1580/3 Prague160 00 Czech Republic Fraunhofer Institute for Machine Tools and Forming Technology IWU Department of Production Digital Twin Nöthnitzer Straße 44 Dresden Germany Technische Universität Dresden Institute of Mechatronic Engineering Chair of Machine Tools Development and Adaptive Controls Dresden01062 Germany

The machining of high-value products needs advanced quality control to avoid the risk of expensive follow-up operations performed on parts with unacceptable quality. This situation requires the in-process or close to in-process control of the machining operation. The tangential cutting force is a parameter that characterizes the force interaction between the specific workpiece material and the specific tool geometry. This paper presents a method for a tangential cutting force calculation along the given tool path based on processing of the high-frequency data acquired from the machine tool control system with support of the geometric material removal model. The calculated data are compared with the reference dynamometer results. The influence of the variable engagement parameters is demonstrated and discussed from the perspective of the in-process workpiece quality control. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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Direct laser interference patterning of cemented cutting tools 17

Direct laser interference patterning of cemented cutting too...

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Laser-based Micro- and Nanoprocessing XVII 2023

作者： Baumann, Robert Bouraoui, Yasmine Teicher, Uwe Selbmann, Erik Ihlenfeldt, Steffen Lasagni, Andrés Fabián Institute for Manufacturing Technology Technische Universität Dresden George-Baehr-Str. 3c Dresden01069 Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstraße 7a Dresden01069 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Fraunhofer Institute for Material and Beam Technology IWS Winterbergstraße 28 Dresden01277 Germany

ISBN: (纸本)9781510659230

Nowadays, improving processes sustainability has become a major topic for many manufacturers in metal processing industries. Next to the challenging rise of costs of raw material and tools, innovative and hard to process materials enter the market. Here, surface functionalization of cutting tools is devised as a convenient approach for reducing energy consumption as well as material losses. In this work, direct laser interference patterning (DLIP) is used for manufacturing periodic line-like structures with spatial periods of 5.5 µm on tungsten carbide. The texturing is applied on rake-flank faces of the cutting inserts, leading to texture depths up to 1.75 µm by controlling the amount of used laser pulses. Moreover, turning experiments under lubricated conditions carried out on Al 6061 T6 parts with structured and untreated tools are performed to investigate the tribological performance. In result, the used DLIP-functionalized cutting tools could effectively decrease machining forces up to 12 %. This is caused by the corresponding improvement in frictional and improved lubrication behavior at the tool/chip interface. Furthermore, the laser-processed tools generate thinner chips, which leads to a decrease in surface roughness by 31 % of the aluminum work piece. This work thus offers insight into the viability of improving cutting tools by laser surface micro patterning for upcoming innovative materials designed for improving tool wear resistance, energy efficiency and surface quality. © 2023 SPIE.

关键词： Tungsten carbide

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Improvement of cutting tools using laser-induced periodic surface structures for machining Aluminium alloy Al 6061 T6 17

Improvement of cutting tools using laser-induced periodic su...

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Laser-based Micro- and Nanoprocessing XVII 2023

ISBN: (纸本)9781510659230

Improving processes sustainability to address upcoming demands in metal processing industries such as innovative and hard to process materials has become a major topic for many manufacturers. Therefore, new tool material compositions or surface coatings are continuously developed. In this context, surface functionalization of cutting tools is foreseen as a convenient approach for minimizing material losses and thus energy consumption. In this work, laser induced periodic surface structures (LIPSS) are used for manufacturing quasi-periodic line-like patterns on tungsten carbide inserts. The textured tool surfaces show low spatial frequency LIPSS (LSFL) with spatial periods of 500 nm to 600 nm as well as high spatial frequency LIPSS (HSFL) with a spatial period of ~100 nm. Furthermore, the texturing is applied on rake and flank faces of the cutting tools with different offsets to the edge between 0 and 0.2 mm. The wettability analysis reveals a decrease of static contact angles for the used cutting fluid (CIMSTAR) from 38° to 12°, suggesting an improved cooling process during the machining step. In addition, turning experiments under lubricated conditions are carried out on Al 6061 T6 parts to investigate the tribological performance. The used LIPSS-functionalized cutting tools could effectively decrease the main machining forces by 10 %, the feed force by 21 % and the passive force by 9 %. Furthermore, the laser-processed tools generate thinner chips, which leads to a decrease in surface roughness by 31 % of the aluminum work piece. © 2023 SPIE.

关键词： Turning

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Bin Picking Pneumatic-Mechanical Gripper for Industrial Manipulators

Bin Picking Pneumatic-Mechanical Gripper for Industrial Mani...

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2021 International Conference on High technology for Sustainable Development, HiTech 2021

作者： Ivanov, Vladislav Aleksandrov, Angel Bdiwi, Mohamad Popov, Aleksander Rashid, Aquib Pershina, Zhanna Kolker, Aleksey Dimitrov, Lubomir Technical University of Sofia Dept. for Machine Elements and Non-Metallic Constructions Sofia Bulgaria Line 3: Fraunhofer Institute for Machine Tools and Forming Technology Robot System Department Chemnitz Germany Novosibirsk State Technical Universirty Falulty of Automation Russia

ISBN: (纸本)9781665448734

The human body is an advanced and complex machine. A simple task like grasping an object, which is done intuitively, has puzzled researchers for decades. For each object, humans have a suitable grip to grab it optimally and safely. Even for objects which we have never seen before, we can choose the best possible grip and can adapt as the environment changes to get a better grip based on cognition and experience. One of the main capabilities of humans is their ability to learn about unfamiliar things and processes. This capability helps us adapt to different situations and still be able to solve a problem. This works focuses on developing a self-learning robotic system which can replicate the human learning capabilities in a handing-over task. The proposed system consists of two submodules: 1) Vision analysis and environment monitoring, which provides accurate global and local information about the area in which the robot has to hand over the specific object;2) Safe and flexible bin-picking gripper, which handles various objects with complex geometries. The work is a consortium of 3 partners: IWU Chemnitz (Germany), Novosibirsk State Technical University (Russia) and Technical University of Sofia (Bulgaria) under European program *** RUS PLUS 2017 © 2021 IEEE.

关键词： Industrial manipulators

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Hybrid approach to evaluate surface integrity based on grinding power and Barkhausen noise 6th

Hybrid approach to evaluate surface integrity based on grind...

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Heinzel, Jonas Jedamski, Rahel Rößler, Maximilian Karpuschewski, Bernhard Epp, Jérémy Dix, Martin Mapex Center For Materials And Processes University Of Bremen Bibliothekstr. 1 Bremen28359 Germany Leibniz Institute For Materials Engineering Iwt Badgasteiner Str. 3 Bremen28359 Germany Fraunhofer Institute For Machine Tools And Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany

In this paper the potential of a reliable characterization of surface and subsurface properties is presented by measurement of process forces for determining the specific grinding power Pc and the micromagnetic Barkhausen noise in cylindrical grinding trials. Therefore different dressing conditions by grinding with conventional wheel with varying process parameters are investigated. It is shown that an identified lower thermal limit in a Pc-t-diagram (contact time t) to prevent tempering zones in the ground surface and subsurface area of case hardened steel is applicable even if the condition of the grinding wheel is intentionally influenced by dressing. Finally a soft sensor concept for the use of the specific grinding power and in perspective also the use of the Barkhausen noise for process control is derived. © 2022 The Authors.

关键词： Grinding (machining)

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Laser structuring with DLIP technology of tungsten carbide with different binder content 12

Laser structuring with DLIP technology of tungsten carbide w...

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12th CIRP Conference on Photonic Technologies, LANE 2022

作者： Teicher, Uwe Baumann, Robert Bouraoui, Yasmine Achour, Anas Ben Lasagni, Andrés Fabián Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany Institute for Manufacturing Technology Technische Universität Dresden George-Baehr-Str. 3c Dresden01069 Germany Fraunhofer Institute for Material and Beam Technology IWS Winterbergstraße 28 Dresden01277 Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstraße 7a Dresden01069 Germany

In machining, tool wear is one of the main influence factors for the resulting quality of the product. Several wear mechanisms have to be addressed to prevent unwanted deterioration of the tool integrity. For aluminium alloys, adhesion of the workpiece material on the cutting tool is one of the most challenging wear mechanisms. Engineering surface microtopographies has been proved as a convenient strategy to tackle this issue. Particularly, the direct laser interference patterning (DLIP) technique enables the integration of periodic structures on the micrometer or sub-micrometer scale. In this study the structuring of tungsten carbide with different cobalt content is presented. The interference of two laser beams leads to periodic line-like structures with a spatial period of 5.5 µm. A maximum structure depth of 2.2 µm is reached by controlling the processing parameters. Moreover, the wettability of the structured samples was analyzed by contact angle measurements with selected cooling lubricants, revealing a hydrophilic behavior with a decreased contact angle of 10°. This work gives an insight into the possibilities of structuring tungsten carbide materials with a picosecond laser source in combination with an innovative beam shaping setup from the point of view of an analysis to explore the formation of structured surfaces and their wetting behavior with cooling lubricants. © 2022 The Authors. Published by Elsevier B.V.

关键词： Tungsten carbide

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Influence of engagement parameters on estimation of tangential cutting force using high-frequency process data of the machine tool

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Procedia CIRP 2023年 118卷 537-542页

作者： Michal Rytir Jonas Rönnecke Albrecht Hänel Petr Kolar Steffen Ihlenfeldt Czech Technical University in Prague Czech Institute of Informatics Robotics and Cybernetics Department of Industrial Production and Automation Jugoslávských partyzánů 1580/3 160 00 Prague Czech Republic Fraunhofer Institute for Machine Tools and Forming Technology IWU Department of Production Digital Twin Nöthnitzer Straße 44 Dresden Germany Technische Universität Dresden Institute of Mechatronic Engineering Chair of Machine Tools Development and Adaptive Controls 01062 Dresden Germany

关键词： In-process monitoring leakage model cutting force model spindle current edge computing

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Hybrid approach to evaluate surface integrity based on grinding power and Barkhausen noise

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Procedia CIRP 2022年 108卷 489-494页

作者： Jonas Heinzel Rahel Jedamski Maximilian Rößler Bernhard Karpuschewski Jérémy Epp Martin Dix MAPEX Center for Materials and Processes University of Bremen Bibliothekstr. 1 28359 Bremen Leibniz Institute for Materials Engineering IWT Badgasteiner Str. 3 Bremen 28359 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

In this paper the potential of a reliable characterization of surface and subsurface properties is presented by measurement of process forces for determining the specific grinding power Pc” and the micromagnetic Barkhausen noise in cylindrical grinding trials. Therefore different dressing conditions by grinding with conventional wheel with varying process parameters are investigated. It is shown that an identified lower thermal limit in a Pc” - ∆t -diagram (contact time ∆t ) to prevent tempering zones in the ground surface and subsurface area of case hardened steel is applicable even if the condition of the grinding wheel is intentionally influenced by dressing. Finally a soft sensor concept for the use of the specific grinding power and in perspective also the use of the Barkhausen noise for process control is derived.

关键词： grinding burn detection surface integrity process control

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Laser structuring with DLIP technology of tungsten carbide with different binder content

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Procedia CIRP 2022年 111卷 601-604页

作者： Uwe Teicher Robert Baumann Yasmine Bouraoui Anas Ben Achour Andrés Fabián Lasagni Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 01187 Dresden Germany Institute for Manufacturing Technology Technische Universität Dresden George-Baehr-Str. 3c 01069 Dresden Germany Fraunhofer Institute for Material and Beam Technology IWS Winterbergstraße 28 01277 Dresden Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstraße 7a 01069 Dresden Germany

关键词： Laser structuring cutting tool DLIP Surface modification tungsten carbide

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Additive manufacturing technologies for next-generation powertrains

Additive manufacturing technologies for next-generation powe...

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International Electric Drives Production Conference (EDPC)

作者： Philipp Fiedler Sebastian Stelzer Nikolaus Milaev Robert Richter Frank Kaulfuß Thomas Windisch Jan Bräunig Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany 3D-Printpetrol Großenhain Germany Fraunhofer Institute for Material and Beam Technology IWS Dresden Germany Division Engineering of Adaptive Systems Fraunhofer IIS/EAS Fraunhofer Institute for Integrated Circuits Dresden Germany

ISBN: (数字)9781728184586

ISBN: (纸本)9781728196145

The paper addresses the prototypical development and implementation of an innovative and functionally integrated gear stage for next-generation electric vehicles, produced by using Laser Beam Melting (LBM) and Fused Deposition Modeling (FDM). Two new design targets are addressed by our approach: Oil-free operation is achieved by innovative coating of gear teeth which enables almost maintenance-free operation. Furthermore, a higher damping of sound transmission from tooth mesh to bearings is implemented by an optimal wheel body geometry that is realized by a combination of printable carbon-containing polymers (flange) and steel (gear rim). The innovative approach is to extend components by areas that cannot be produced by milling and casting, e.g. complex structures, contour-following fluid-carrying cooling elements by means of LBM, thus creating a significant benefit compared to state-of-the-art gearboxes. Function integration made possible by additive manufacturing results in a very high component complexity. It is combined with gear grinding and final ta-C coatings ensuring maximum efficiency in dry operation, to achieve economically viable production processes. The increase in tooth mesh efficiency is achieved by optimization approaches in the design to minimize heat losses while at the same time maintaining highest possible strength and lowest noise emission.

关键词： Gears Wheels Production Three-dimensional printing Laser beams Coatings Next generation networking

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