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

作者： Trân, Ricardo Kertsch, Lukas Marx, Sebastian Hebbar, Shreyas Psyk, Verena Butz, Alexander Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Fraunhofer Institute for Mechanics of Materials IWM Wöhlerstraße 11 Freiburg79108 Germany

ISBN: (纸本)9783030753801

Manufacturing technologies for parts made from ultra-high-strength 7xxx series aluminum sheet material have been the focus of research in recent years. A promising approach is W-temper forming, where sheet material is cold formed after heat treatment. Conventional heat treatment routes are very time-consuming and inefficient. In this study, a new more efficient and industry-orientated transfer tool concept has been developed. Heating and cooling of the sheets take place in separate contact tempering stages, which allow superior heating and cooling rates in comparison to conventional methods. To analyze the influences of temperature rates and deformation on microstructure and mechanical behavior, thermo-mechanical experiments in a Gleeble simulator were carried out. The results prove the great potential of the transfer tool concept with inline heat treatment for series production. The process-dependent mechanical properties determine a suitable process window for the industrial application of the W-temper forming of the analyzed alloys. © 2021, The Minerals, Metals & Materials Society.

关键词： Industrial research

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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

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.

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

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Objective validation for short-term material flow simulation

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Procedia CIRP 2025年 134卷 526-531页

作者： Heiner Reinhardt Boran Bogdanow Roman Arnold Bastian Prell Philipp Klimant Frank Seifert Mahtab Mahdaviasl Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany Volkswagen Sachsen GmbH Kauffahrtei 47 09120 Chemnitz Germany Technical University of Applied Sciences Wildau Hochschulring 1 15745 Wildau Germany Professorship Virtual Technologies Hochschule Mittweida - University of Applied Sciences Technikumplatz 17 09648 Mittweida Germany Chemnitz University of Technology Straße der Nationen 62 09111 Chemnitz Germany Institute of Machine Tools and Control Engineering Technische Universität Dresden Helmholtzstraße 7a 01062 Dresden Germany

Material flow simulation, by means of discrete event simulation (DES), is utilized in various industries to support production planning and control. This is due to the fact that changes to manufacturing systems and production strategies can be virtually examined before actual implementation. Since the manual development and repeated adjustment of simulation models is time-consuming and error-prone, numerous studies suggest computerized model generation and synchronization. However, validation of such generated or synchronized models is rarely considered. Here, we present an extendible objective validation technique for the repeated short-term simulation of a generated model. To illustrate this, the technique is applied to a high-volume automotive production line and a series of simulation cycles.

关键词： Digital Twin Simulation Quality Optimization Manufacturing system Control Analysis

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Generative design in factory layout planning

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Procedia CIRP 2021年 99卷 9-14页

作者： Marian Süße Matthias Putz Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

Planning and optimization of facility layouts have been investigated for decades and manifold approaches are applied for structuring and design of production layouts. However, results heavily depend on the experience and creativity of involved planning experts. Currently, complexity of planning processes constantly increases, e.g. due to further requirements of energy and media supply. Generative Design, hitherto mainly applied in component development, provides opportunities to cope with a much larger solution space and develop creative layout concepts. Thus, based on a structured overview on established planning methods, a concept and first results of factory layout planning with Generative Design are described.

关键词： Generative design Computational design Evolutionary design Factory planning Layout planning Literature search

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A CAD-based workflow and mechanical characterization for additive manufacturing of tailored lattice structures 29

A CAD-based workflow and mechanical characterization for add...

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29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2018

作者： Koch, P. Korn, H. Kordass, R. Holtzhausen, S. Schoene, C. Mueller, B. Stelzer, R. Institute of Machine Elements and Machine Design TU Dresden Dresden Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany

Lattice structures are highly recommended for lightweight applications and cost reduction in additive manufacturing (AM). Currently, parts with lattice structures are still mainly used for illustrative purposes and rarely in industrial products. One important reason is that, due to their high dependency on macro- and micro-geometry, the mechanical properties of manufactured structures are difficult to predict. Thus, even and precise struts are needed. In this paper, a workflow for fabrication of lattice structures with strut-diameters from 150 µm to 400 µm on commercial laser beam melting (LBM) systems is presented. Based on a CAD-integrated user-interface for lattice design, a customized slicing algorithm determines database-aided suitable exposure parameters which ensure that the properties of the manufactured struts will just be as specified upon design. Subsequently, compression tests are performed in order to verify the established workflow. The developed tool enables designers to integrate AM-specific geometries into their components with little specific experience in AM. © Solid Freeform Fabrication 2018: Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, SFF 2018. All Rights Reserved.

关键词： 3D printers

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Software assisted clamping point classification and position optimization for the efficient flexibilization of carbody fixtures using mathematical geometry-based search algorithms

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Procedia CIRP 2021年 99卷 466-471页

作者： Rayk Fritzsche Robert Schaffrath Marcel Todtermuschke Head of group Assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Scientific employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany Head of dep. Assembly systems at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz 09126 Germany

The Fraunhofer IWU has been developed specialized clamping robots for production of different car-models on one fixture. One of the challenges with universal clamping of different components is the contact point between part and clamping device. For the optimization of the clamping contours, a software was developed with which the geometries of the clamping points can be automatically analyzed and classified. With target search criteria, the clamping position on the component can be changed so that the clamping contours are geometrically simplified. Thus, a huge reduction in the complexity of the flexible clamping device is possible.

关键词： Body in white Automated device design Analysis software Optimization Product flexibility

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Exposure to industrial noise: Impacts on cognitive performance 50

Exposure to industrial noise: Impacts on cognitive performan...

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

作者： Pereira, Luiz Henrique Mesa Casa Knöfel, Björn Troge, Jan Drossel, Welf-Guntram Klein, Marcel Hübelt, Jörn Fraunhofer Institute for Machine Tools and Forming Technology IWU Nöthnitzer Straße 44 Dresden01087 Germany Mittweida University of Applied Sciences Technikumplatz 17 Mittweida09648 Germany

ISBN: (纸本)9781732598652

Research on the relation between exposure to noise and cognitive performance inside industrial environments is not as broad as on office environments. For a better understanding of the specific industrial noise problems, 23 participants performed arithmetic tests inside a hemi anechoic room while they were exposed to a sequence of sound from five typical industrial noise sources. The subjects also classified how annoying they perceived the noise signals. The effects of noise on the arithmetic test's performance of the 23 participants was found on accuracy and on velocity, although the p-values of a Student t-test are comparable high. Dividing the subjects into a group of more noise annoyed resp. a group of less noise annoyed participants revealed significant influences of the presence of noise compared to an initial test without noise. The more annoyed subjects exhibit a drop of accuracy (-4%, p=0.017) while the less annoyed subjects increase significantly their velocity in the test (+15%, p=0.001). Subjects that evaluated noise as more annoying performed worse in a final arithmetic test (under silence) after being exposed to the noises, indicating a possible cumulative effect of noise on performance. The findings provide a better insight in the cognitive behavior of people who are exposed to industrial noise. Hence, the study will proceed with the specific noise analysis of single industrial workplaces. © INTER-NOISE 2021 .All right reserved.

关键词： Testing

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Impact of Cyber-physically enhanced manufacturing on the product requirement documentation in high-tech applications 18

Impact of Cyber-physically enhanced manufacturing on the pro...

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18th CIRP Conference on Modeling of Machining Operations, CMMO 2021

作者： Hänel, Albrecht Seidel, André Mehling, Carl Willy Dementyev, Alexander Kozak, Karol Seidel, Rudi Teicher, Uwe Hellmich, Arvid Drossel, Welf-Guntram Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden01187 Germany Technische Universität Dresden Center for Evidence-based Healthcare Dresden01307 Germany Technische Universität Chemnitz Institute for Machine Tools and Production Processes Chemnitz09126 Germany Technische Universität Dresden Institute of Mechatronic Engineering Dresden01062 Germany

Conventional machining of high-tech parts and components is often associated with complex processes, long lead times and small to medium batch sizes. Obviously, there is great interest to shorten process development periods and increase process reliability. The transformation of conventional machines into cyber-physical production systems (CPPS) promises significant improvements here. In fact, CPPS allows real-time data acquisition and processing, enabling to target integrated process improvement and quality assurance. In the present work, a methodical procedure for structured data aggregation is introduced for a Cyber-physical enhanced machining process while being explained from a high-tech application point of view. This includes data generation, extraction, transfer and storage, data-consolidation, linkage, visualization and interpretation. Finally, the paper illustrates these aspects in terms of the effects on the "digital product requirements" in order to achieve the presented "analytics-ready" data model using the example of a high-tech application. © 2021 Elsevier B.V.. All rights reserved.

关键词： Data acquisition

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

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Procedia CIRP 2024年 128卷 132-137页

作者： Gibson P. Chirinda Stephen Matope Philani Zincume Whisper Maisiri Andreas Sterzing University of Stellenbosch Private Bag X1 Matieland Stellenbosch 7602 South Africa North West University Private Bag X6001 Potchefstroom 2531 11 Hoffman Street South Africa Fraunhofer Institute of Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz 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.

关键词： topology optimization material substitution lightweighting automotive industry

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Evaluation of augmented reality supported approaches for product design and production processes

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Procedia CIRP 2021年 97卷 160-165页

作者： Marco Schumann Christian Fuchs Christian Kollatsch Philipp Klimant Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Straße 70 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 09126 Chemnitz Germany

Augmented Reality (AR) has been a focus of research in the field of production for many years with the goal to improve e.g. monitoring and maintenance processes. Although the benefits have been well researched, the AR technology has not been widespread yet in the industry. This article discusses reasons why existing approaches have not become established outside the research context. Following this, solutions are examined for three identified problematic areas. First, this article presents a theoretical method to create use cases for AR applications in the product design process based on the Double Diamond design process model. The second main part discusses which device properties are relevant for a production environment. A catalogue of criteria is presented, weighting properties according to their importance. Third, a discussion is described regarding data integration concepts, problems and solutions for AR design and production use cases.

关键词： Augmented reality Production Design Double Diamond design process model

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