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27th International Congress on Sound and Vibration, ICSV 2021

作者： Georgi, Oliver Rüger, Carlo Rentzsch, Hendrik Hochmuth, Carsten Putz, Matthias Dix, Martin Papsdorf, Gunther Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany SINUS Messtechnik GmbH Leipzig Germany

ISBN: (纸本)9788378807995

Regarding deep drilling, problems in terms of chip formation and removal, burrs, tool vibrations as well as process reliability occur. Modern scientific approaches face these problems and aim to improve productivity, quality and reliability to reduce manufacturing costs. At the same time, there is a trend to use in-process monitoring and control in terms of adaptive machining processes in order to operate cutting processes close to the limits of stability. The application of ultrasonic assistance for drilling and deep drilling processes enables multiple advantages like reduced tool wear and burr formation as well as enhanced chip breaking behaviour. Moreover, ultrasound enables the use of previously unused physical effects to obtain information from the process zone and identify process conditions. In this context, the paper presents an approach of using modulation phenomena to evaluate dynamic process stability, using ultrasound as a carrier signal for low-frequency vibrations related to the deep drilling tool. In addition, the resonant coupling of ultrasonic system and cutting operation is used to draw direct conclusions about the load behaviour of the machining process from characteristics of the resonant vibration system. This directly leads to the possibility to perform in-process monitoring of tool wear. The article covers the theoretical basics, the hardware realization as well as experimental investigations regarding acoustic process monitoring for ultrasonic-assisted deep drilling. © "Advances in Acoustics, Noise and Vibration - 2021" Proceedings of the 27th International Congress on Sound and Vibration, ICSV 2021. All rights reserved.

关键词： Process monitoring

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Increasing Resilience of Production Systems by Dynamic Context Modelling and Process Adaption 16

Increasing Resilience of Production Systems by Dynamic Conte...

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

作者： Wunderlich, Tim Hansert, Jonas Koch, Sandro Heinrich, Robert Schlegel, Thomas Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany Karlsruhe University of Applied Sciences Moltkestr. 30 Karlsruhe76133 Germany Karlsruhe Institute of Technology Am Fasanengarten 5 Karlsruhe76131 Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden01062 Germany

The requirements for cyber-physical production systems (CPPS) grow steadily, leading to increased complexity of such systems. To address issues due to reconfiguration or failures, we present an approach to creating a context model of the CPPS components during runtime and to detect deviations from the planned production processes. Furthermore, we present a concept for modelling production processes that allows for dynamic process adaption during runtime. We then utilize this process adaption and the context model to cope with unforeseen failures and increase the resilience of the system. Finally, we evaluate the feasibility of our approach by applying it to an Industry 4.0 production system. © 2023 Elsevier B.V.. All rights reserved.

关键词： Dynamics

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UV-Imprint of micro-textured polymer films for biomedical disposables 22

UV-Imprint of micro-textured polymer films for biomedical di...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Gärtner, Eric Edelmann, Jan Hackl, Claudia Roussak, Liudmila Tomasova, Lea Guttenberg, Zeno Gnüchtel, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Leipzig Germany SensLab GmbH Leipzig Germany Ibidi GmbH Gräfelfing Germany WESKO GmbH Stollberg Germany

ISBN: (纸本)9781998999118

In the life science sector, increasing demands on the reproducibility and accuracy of lab-on-chip systems require new manufacturing technologies for the production of polymer films with multifunctional surfaces. A mass-production capable and cost-effective way to pattern microfluidic films is the manufacturing process of UV injection molding. Therefore, the aim of the project is to develop microstructured polymer films with multifunctional surface properties by means of an injection molding UV plate-to-plate (P2P) replication process. For this purpose, a special film injection molding system was developed that allows filling with different formulations, curing by UV light and molding of the required microstructures. In respect to the application of the microstructured polyacrylate films in cell-based assays as well as biosensor disposables, microstructures of various geometries were designed and produced in the P2P process. In addition, cell tests were performed in this study in order to evaluate the biocompatibility and optical quality of the substrates, and to verify the functionality of the microstructures. Here, we show that the structured polyacrylate foil is a suitable substrate that can be implemented in plastic microfluidic chips for cell-based assays and biosensor disposables. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Polymer films

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Influence of clearance and velocity during blanking on the fatigue behavior of cellulose-based biocomposites

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Procedia CIRP 2024年 125卷 54-59页

作者： Ronja Scholz Sven Winter Alexander Delp Tobias Breitfeld Verena Psyk Welf-Guntram Drossel Frank Walther Chair of Materials Test Engineering (WPT) TU Dortmund University Baroper Str. 303 D-44227 Dortmund Germany Fraunhofer Institute for Machine Tools and Forming Technology (IWU) Reichenhainer Strasse 88 D-09126 Chemnitz Germany Institute for Machine Tools and Production Processes (IWP) Chemnitz University of Technology Reichenhainer Strasse. 70 D-09126 Chemnitz Germany

Cellulose-based biocomposites, such as Cottonid, are a promising class of materials to improve the carbon footprint of products during their service life. Cottonid has high technological potential due to its physical and mechanical similarities to engineering plastics and light metals. To replace traditional metallic materials in industry, cellulose-based semi-finished products need to be formed and cut. In particular, blanking is the most cost-effective and industrially common cutting method for metals. However, this study investigates the influence of various blanking process parameters on the quality and the fatigue strength of the resulting cutting edges of Cottonid. The presented results give insights on how the relationships between process parameters during cutting and resulting material properties known from conventional materials can be transferred to cellulose-based biocomposites like Cottonid. The relative clearance was varied between 4 and 10% and the cutting velocity between 0.05 and 10 m/s. It was evident that slower velocities and smaller clearances resulted in visibly better cutting edges. In order to relate this effect to the mechanical performance of Cottonid, new 3-point bend specimens were taken from the blanked strips for fatigue testing. It was found that the fatigue strength was significantly affected by the velocity and clearance. Further, similar to metallic materials, clean-cut (smooth area) and a fractured zone can be clearly distinguished. A good cutting edge quality results in a higher resistance of the Cottonid component against crack initiation at process-induced defects. The knowledge gained may enable an efficient cutting process for cellulose-based materials with higher fatigue strength in the future.

关键词： Cottonid Cellulose Shear Cutting High-Speed Impact Cutting Fatigue Cutting Edge Quality

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Study on flushing condition for improving silver deposition in silver nano-powder mixed EDM 22

Study on flushing condition for improving silver deposition ...

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22nd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2022

作者： Bui, Viet D. Meinshausen, Ann-Kathrin Berger, Thomas Martin, André Harnisch, Karsten Bertrand, Jessica Schubert, Andreas Chemnitz University of Technology Institute for Machine Tools and Production Processes Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Otto-von-Guericke University Magdeburg Department of Orthopaedic Surgery Leipziger Str. 44 Magdeburg39120 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9781998999118

Silver nano-powder mixed electrical discharge machining (PMEDM) has demonstrated its applicability for antibacterial surface modification. However, previous PMEDM studies indicated that jet flushing leads to a low powder concentration in the spark gap, which was the main reason for a low deposited silver content. Internal flushing with different dielectric pressures was therefore proposed and will be investigated in this study. To do so, Ti-6Al-4V hollow tool electrodes with an outer diameter of 3 mm and an inner diameter of 2.5 mm are selected to machine Ti-6Al-4V samples. Silver nano-powders with a size of 50 nm to 60 nm are suspended in the hydrocarbon-based dielectric fluid at a 5 g/l powder concentration. Surface roughness and resulting silver content and distribution on the modified surface are analysed and discussed. Results show that internal flushing significantly increases the deposited silver content when high pressure of the dielectric fluid was applied. In addition, with careful control, the internal flushing is a promising strategy for improving the uniformity of the deposited silver distribution. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Surface roughness

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Effects of abrasive waterjet cutting on surface properties of hardened steel

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Procedia CIRP 2023年 118卷 620-625页

作者： Nermin Redžić Philipp Kieweg Joachim Regel Martin Dix Chemnitz University of Technology Institute for Machine Tools and Production Processes Reichenhainer Str. 70 09126 Chemnitz Germany Franke GmbH Obere Bahnstraße 64 73431 Aalen Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany

The importance of cutting hardened materials without influencing their structural properties makes abrasive waterjet machining a favorable choice in certain applications in comparison with other manufacturing technologies. Using this technology, faulty surface structures and errors caused by high thermal loads such as burrs, burns and cracks, can be avoided. In this paper, the results of applying the abrasive waterjet technology for cutting of hardened steel and its advantageous properties in comparison with cut-off grinding will be presented. The influence of process parameters on surface properties and burr formation has been determined by experimental analysis.

关键词： abrasive waterjet machining hardened steel cut-off grinding burr formation

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Incremental Collar forming Process for the Manufacturing of Branched Tubes and Pipes 13th

Incremental Collar Forming Process for the Manufacturing of ...

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13th International Conference on the technology of Plasticity, ICTP 2021

作者： Leonhardt, André de Witt, Peggy Rehm, Matthias Schlegel, Holger Kräusel, Verena Professorship Forming and Joining Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz Germany Professorship Production Systems and Processes Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz Germany

ISBN: (纸本)9783030753801

Beside the manufacturing of finished parts by Incremental Sheet Metal forming (ISF), final operations within the process chain can also be realized with this technology. The technological capabilities of performing incremental (hole-)flanging operations for sheet metal parts has been investigated in research context. The current topic focusses on the transfer of the incremental forming technology to manufacture tubular parts. An incremental collar forming process was developed where all motions are executed by the forming tool. Due to the fixed position of the workpiece, tubes, as well as pipes can be branched. Stainless steel tubes made of 1.4404 (316L) with an outer diameter of 54 mm and a wall thickness of 1.5 mm were used for experimental evidence of functional capability of the incremental collaring process. The influence of different pre-hole geometries and forming tool shapes on the properties of the collar (e. g. geometrical accuracy, wall thickness) was investigated. © 2021, The Minerals, Metals & Materials Society.

关键词： Tubular steel structures

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Comparative analysis of topology optimization versus material substitution: Is there a best method for vehicle weight reduction? 34

Comparative analysis of topology optimization versus materia...

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34th CIRP Design Conference, CIRP 2024

作者： Chirinda, Gibson P. Matope, Stephen Zincume, Philani Maisiri, Whisper Sterzing, Andreas University of Stellenbosch Private Bag X1 Matieland Stellenbosch7602 South Africa North West University Private Bag X6001 11 Hoffman Street Potchefstroom2531 South Africa Fraunhofer Institute of Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The United Nations (UN) Sustainable Development Goal 13 focuses on taking urgent action to combat climate change and its impacts. Resource efficient production and strict emission regulations have made vehicle weight reduction a subject of great interest. Common lightweighting techniques include topology optimization and material substitution. The benefits include reduced raw material usage, low fuel consumption, and low carbon emissions. There is a gap in the complex balance of decision-making. If an engineer is faced with the option of topologically optimizing or materially substituting, is one method better than the other? This paper comparatively analyses these lightweight design strategies. © 2024 Elsevier B.V.. All rights reserved.

关键词： Low emission

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Test bench development and validation for blocked force measurements in six degrees of freedom 50

Test bench development and validation for blocked force meas...

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50th International Congress and Exposition of Noise Control Engineering, INTER-NOISE 2021

作者： Burkhardt, Martin Hensel, Eric Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Str. 44 Dresden01187 Germany

ISBN: (纸本)9781732598652

For transfer path analysis (TPA) methods, the description of the source is essential. The possibilities of source characterization are as different as the TPA methods. For the classical methods, the source is considered in the assembled state with feedback from the receiver structure, while for component-based TPA the source is described without feedback from the coupled structure. In addition to TPA, source characterization is also used in the product development process for evaluation or comparisons. Also in these cases, the source must be characterized without feedback from the test structure, which can generally be realized by measuring free velocities or blocked forces. Because of the need for an external load to reach the components operating point, force measurements are often used. However, the realization of a test setup without significant influences on the measurement of forces poses some challenges. The paper presents a setup that can be used to perform a direct force measurement at one point in six degrees of freedom (dof). The necessary boundary conditions to approximate the idealized blocked force assumption are discussed, the calculation of the blocked force in six dof is presented, the structural dynamic response at a reference point is calculated and compared with operational measurements. © INTER-NOISE 2021 .All right reserved.

关键词： Force measurement

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Development of general data-based process models for self-pierce riveting 24

Development of general data-based process models for self-pi...

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24th International ESAFORM Conference on Material forming, ESAFORM 2021

作者： Jäckel, Mathias Falk, Tobias Kropp, Thomas Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01187 Germany

ISBN: (纸本)9782870193020

The determination of ideal process parameters for mechanical joining processes such as self-pierce riveting currently requires a comprehensive understanding of the process, the availability of the materials to be joined and the corresponding system technology. General process models can simplify the use of these joining technologies, accelerate development cycles and thereby reduce the effort for implementation into production. In this paper, the development of general data-based process models for the mechanical joining method self-pierce riveting with semi-tubular rivet is described. Extensive experimental and numerical investigations with more than 2300 joint combinations for steel and aluminum sheets with tensile strengths between 240 - 1020 MPa were generated for the building of the models. Based on these results, different meta-models are fused into general data-based process models for the self-pierce riveting process in order to show the general relationships between material properties, process parameters and joining results. The paper discusses the acquisition of the experimental and numerical data, the statistical methods for evaluation and the application of the data-based process models. © ESAFORM 2021 - 24th Inter. Conf. on Mat. forming. All rights reserved.

关键词： Riveting

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