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International Electric Drives Production Conference (EDPC)

作者： Mirko Bach Maik Linnemann Markus Bergmann Verena Psyk Verena Kräusel Niclas Pohl Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (纸本)9781665418102

The steadily growing use of industrial electric motors worldwide, combined with the need for improved efficiency, require advanced technologies that are beneficial with regard to resource efficiency and productivity. One possibility for saving raw materials is to reduce the size and weight of motors while maintaining the same performance. This can be achieved through an increase of the so-called slot filling factor, which has substantial influence on the torque generation in the electric machine. One way of increasing the slot filling factor is to shape the respective conductors in such a way that the cross sections correspond to their position. The focus of this paper lies on the description of interactions in the forming process of tooth coils with trapezoidal cross section geometry of the individual turns. In particular, the shaping of the coil heads of coils produced by sequential forming and subsequent bending is characterized via FEM forming simulation. Furthermore, the contribution presents a possibility for manufacturing coils of different geometries at high output rate by using flexible forming operations. Compared to manufacturing process chains suggested earlier, this approach allows considerable shortening and optimization of the process chain.

关键词： Coils Geometry Torque Shape Windings Wires Bending

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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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Mycelium-based-composites – Vision for substitution of fossil-based materials

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Procedia CIRP 2024年 125卷 78-83页

作者： Steffen Ihlenfeldt Stefan Schillberg Christoph Herrmann Simon Vogel Robar Arafat Simon Harst Chair of Machine Tools Development and Adaptive Controls Insitute of Mechatronic Engineering TU Dresden Helmholtzstraße 7a 01069 Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Pforzheimer Str. 7a 01189 Dresden Germany Chair of Molecular Biotechnology Worringerweg 1 RWTH Aachen University 52074 Aachen Germany Fraunhofer Institute for Molecular Biology and Applied Ecology IME Forckenbeckstr. 6 52074 Aachen Germany Chair of Sustainable Manufacturing & Life Cycle Engineering Institute of Machine Tools and Production Technology IWF Technische Universität Braunschweig Langer Kamp 19b 38106 Braunschweig Germany Fraunhofer Institute for Surface Engineering and Thin Films IST Riedenkamp 2 38108 Braunschweig Germany

For decades, fossil-based materials have formed the basis of an almost endless range of technical products. Through variable chemical composition and several additives, especially plastics can have a wide range of properties, which form the basis for the diversity of plastic-based products. While this variability enables many sustainability strategies, such as lightweighting, it is also impeding a fully circular economy. Therefore, in recent years, a number of new raw materials have been developed, but they can only cover a very limited part of the wide range of properties of fossil-based plastics. Another promising class of materials are composites based on fungal mycelium. However, these are mainly limited to the consumer sector, e.g. vegan leather, where there is smaller demand for durability, functionality etc. The step from consumer to engineering materials require the production (or growth) process to be reproducible within the necessary quality requirements. Cyber-physical production systems have the potential to realise necessary technical qualities despite e.g. quality fluctuations of the raw material and production processes that are susceptible to interference. For this reason, this paper analyses the state of the art in production of mycelium based composites, shows the existing gaps and draws a vision to close these gaps.

关键词： cyber-physical production biological transformation mycelium-based composites

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Usage-based leasing of complex manufacturing systems: A method to transform current ownership-based into pay-per-use business models 55

Usage-based leasing of complex manufacturing systems: A meth...

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55th CIRP Conference on Manufacturing Systems, CIRP CMS 2022

作者： Alaluss, Mohaned Drechsler, Chris Kurth, Robin Mauersberger, Anton Ihlenfeldt, Steffen Marré, Michael Labs, Rainer Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Institute of Mechatronic Engineering Technische Universität Dresden Helmholtzstr. 7a Dresden01069 Germany South Westphalia University of Applied Sciences Frauenstuhlweg 31 Iserlohn58644 Germany

Manufacturing technology with its cost- and resource-intensive manufacturing machines like machine tools, whose amortization often takes several years, is characterized by a high degree of individualization. Here, the need for increasingly complex as well as individualized products leads to the demand for high flexibility and resilience in complex manufacturing systems. The increasing uncertainty and volatility in the markets pose high economic risks for machine operators with ownership-based business models to enter new technologies. Consequently, this restrains the innovative and creative power of manufacturing companies. Although leasing models exist in various industry sectors like printing industry or compressed air supply, their implementation is still challenging due to the high degree of complexity regarding machine system, process, and services of the leasing product. In this paper, a novel method, with increased consideration of technical-technological aspects, to transform current ownership-based into usage-based business models like pay-per-use, is proposed. The resulting method also considers the pay-per-use readiness through an initial assessment of the existing manufacturing system. © 2022 The Authors. Published by Elsevier B.V.

关键词： agile production business models industry 4.0 machine tools manufacturing machines method pay-per-use perfomance-based contracting

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Apparatus to measure wear of soft tissue induced by reconstruction plates – A preliminary study

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Procedia CIRP 2024年 125卷 290-295页

作者： Anas Ben Achour Allani Mohamed Hedi Uwe Teicher Günter Lauer Christian Bräuer Tom Alexander Schröder Fraunhofer Institute for Machine Tools and Forming Technology IWU 01187 Dresden Germany Oral and Maxillofacial Surgery Faculty of Medicine Carl Gustav Carus TU Dresden 01307 Dresden Germany Department of Oral and Maxillofacial Surgery Facial Plastic Surgery University of Rostock Schillingallee 35 18057 Rostock Germany

Mandibular reconstruction is a complex surgical procedure that aims to restore form and function. This procedure becomes necessary in cases where significant bone loss or defects occur due to medication-related osteonecrosis or severe cases of osteomyelitis, tumor resection, or congenital abnormalities. In the last decades, advancements in surgical techniques, materials, and technologies have greatly improved the outcomes of mandibular reconstruction. Nevertheless, complications such as the subsequent formation of large soft tissue wounds regularly occur after the successful treatment of these bone defects. These wounds occur as a result of the relative movements that naturally happen between the implant and the soft tissue, causing the soft tissue to wear away. However, the factors that promote or delay wear have not yet been conclusively clarified. In this work, a test bench was developed and evaluated to simulate naturally occurring movements between implant materials and soft tissue. Then, this test bench was used to compare the wear behavior of linear titanium plates with the behavior of titanium plates encased with bone cement (Palacos®) in a preliminary study. The friction coefficients for different movement patterns of the two surgical techniques were measured and the wear on the abdominal skin of pigs was examined. The results revealed that encasing the titanium plates with bone cement has advantages in terms of friction coefficients and wear for certain movement patterns.

关键词： Bio-based cooling lubricants tribology friction process forces tool wear

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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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Influence Estimation In Multi-Step Process Chains Using Quantum Bayesian Networks

Influence Estimation In Multi-Step Process Chains Using Quan...

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2022 Informatik in den Naturwissenschaften, INFORMATIK 2022 - 2022 Computer Science in the Natural Sciences, INFORMATIK 2022

作者： Selch, Maximilian Müssig, Daniel Hänel, Albrecht Lässig, Jörg Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Digital Production Twin Nöthnitzer Straße 44 Dresden01187 Germany Fraunhofer IOSB Branch Advanced System Technologies IOSB-AST Cognitive Energy Systems Wilhelmsplatz 11 Görlitz02826 Germany

ISBN: (纸本)9783885797203

Digital representatives of physical assets and process steps play a decisive role in analysing properties and evaluating the quality of the process. So-called digital twins acquire all relevant planning and process data, which provide the basis, for example, to investigate path accuracies in manufacturing. Each single process step aims to perform an ideal machining after the specification of a target geometry. However, the practical implementation of a step usually shows deviations from the targeted shape. The machine-learning based method of probabilistic Bayesian networks enables the quality estimation of the holistic process chain as well as improvements by targeted considerations of single steps and influence factors. However, the handling of large-scale Bayesian networks requires a high computational effort, whereas the processing with quantum algorithms holds potential improvements in storage and performance. Based on the issue of path accuracy, this paper considers the modelling and influence estimation for a milling operation including experiments on superconducting quantum hardware. © 2022 Gesellschaft fur Informatik (GI). All rights reserved.

关键词： Bayesian networks

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Experimental validation of characteristic diagram- parameterization for environment-induced thermal interactions on machine tools in a climate chamber

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Procedia CIRP 2021年 99卷 63-68页

作者： Tharun Suresh Kumar Janine Glänzel Robert Tehel Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz 09126 Germany

Thermal gradients created by environmental influences on machine tools cause considerable non-linear thermo-elastic deformations whether the machine is in operation or in idle mode. When a machine tool is subjected to changes in environmental influences such as ambient air temperature, velocity or direction, then flow (CFD) simulations are necessary to effectively quantify the thermal behavior between the machine tool surface and the surrounding air. The conventional two-step simulation procedure consisting of coupled CFD and thermo-elastic simulation is highly time-consuming especially when complex geometries are considered. Decoupling of CFD and thermo-elastic simulation can be achieved by introducing a Clustering Algorithm (CA) and Characteristic Diagrams (CDs) within the simulation workflow. Using training data obtained from a limited number of CFD simulations, the CDs can predict the heat transfer coefficients (HTCs) based on the parameterized environmental influences. This paper attempts to validate the experimental temperature and displacement readings obtained at selected positions on a machine tool using a wide range of metrological equipment such thermography camera, temperature and displacement sensors with the decoupling approach based on parameterized CDs. For investigation, the machine tool is positioned in a climate chamber, which facilitates the variation of environmental influences such as ambient temperature, flow velocity and flow direction. Initially, a precise coupled simulation model is created which is later on converted to a decoupled system using parameterized CDs.

关键词： Decoupling approach CFD-FE simulation Experimental validation Clustering Genetic algorithm

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Extending a factory-based discrete event simulator for parallel optimization of production and supply chain level

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Procedia CIRP 2025年 134卷 885-890页

作者： Omid Safari Marc Münnich Florian Zumpe Yen Mai Thi Pierre Grzona Mario Henrique Callefi Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz Germany University of Applied Sciences Zwickau Faculty of Economics Kornmarkt 1 08056 Zwickau Germany Chemnitz University of Technology Professorship of Factory Planning and Intralogistics Str. der Nationen 62 09111 Chemnitz Germany Dresden University of Technology Institute of Mechatronic Engineering Helmholtzstraße 7a 01069 Dresden Germany

Factory-based discrete event simulation (FB-DES) tools are primarily used to model production systems at the factory level. However, integrating factory activities with supply network optimization has been challenging due to data barriers, leaving the application of FB-DES tools in supply chain (SC) contexts underexplored. This study addresses this limitation by enhancing the capabilities of FB-DES tools to integrate network and factory simulations within a single framework. By incorporating genetic algorithms (GAs) into the simulation model we present an approach to optimize production and supply networks based on key performance metrics such as production cost, time, and resource efficiency. The model features an automated scenario generation system using SimTalk methods and Python scripts to simulate and test potential production scenarios continuously. Additionally, Google Cloud Services (Google Maps API) are utilized for more accurate transportation time calculations, further improving network planning capabilities. This comprehensive simulation framework bridges the gap between factory and SC simulation methods, enhancing performance at both levels. This paper highlights the transformative potential of DES tools augmented with GAs and real-time data, paving the way for more resilient supply and production networks.

关键词： Discrete event simulation Optimization Genetic algorithm Supply chain Siemens Tecnomatix Plant Simulation Automated simulation process

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

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Procedia CIRP 2023年 118卷 282-287页

作者： Tim Wunderlich Jonas Hansert Sandro Koch Robert Heinrich Thomas Schlegel Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 09126 Chemnitz Germany Karlsruhe University of Applied Sciences Moltkestr. 30 76133 Karlsruhe Germany Karlsruhe Institute of Technology Am Fasanengarten 5 76131 Karlsruhe Germany Institute of Mechatronic Engineering Technische Universität Dresden 01062 Dresden 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.

关键词： resilience cyber-physical production systems process adaption context awareness

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