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33rd CIRP Design Conference

作者： Peter, Marie Sauer, Konstantin Regel, Joachim Dix, Martin Institute for Machine Tools and Production Processes Chemnitz University of Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

The use of lightweight materials such as carbon fibre reinforced plastics (CFRP) is increasing due to the demand for rising resource and energy efficiency, especially in the aerospace and automotive industries. Because of the high delamination tendency of these materials and their abrasive impact on the tool, the challenges in machining CFRP lie primarily in the drilling process and thus in the design of the drilling tool. In this paper, an innovative design of a drilling tool for machining CFRP with force-controlled radial feed movement of the cutting edges is presented. The aim of this tool is to create a tool axial force free process that uses a force-controlled radial feed motion, which matches the chip cross-section to the wear condition of the cutting edge. The tool concept is explained based on the functionality of the actuating process. Tests were evaluated with regard to process forces and drilling quality to show that the tool is capable of producing delamination-free bores in a tool axial force free process. © 2023 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://***/licenses/by-nc-nd/4.0)

关键词： Carbon fiber reinforced plastics

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Simulation-Based Improvement of Production in the Tex-Tile Industry—A Case Study 9th

Simulation-Based Improvement of Production in the Tex-Tile I...

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Production Processes and Product Evolution in the Age of Disruption - Proceedings of the 9th Changeable, Agile, Reconfigurable and Virtual Production Conference CARV2023 and the 11th World Mass Customization and Personalization Conference MCPC2023

作者： Grobis, Maxi Münnich, Marc Reinhardt, Heiner Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

ISBN: (纸本)9783031348204

Due to the high volatility of market demand and an increasing individualization, traditional textile manufacturing companies are required to carry out efficient production planning and scheduling (PPS). Highly complex manufacturing operations and a heterogeneous landscape of production equipment in terms of age, technology and automation level as well as a low level of digitalization hamper transparency in PPS, even though the demands on delivery reliability, lead times and flexibility are continuously increasing. Therefore, decision-making is typically based on fragmented production data and practical knowledge of individual workers in daily production that makes overall production opaque. To overcome this, the authors conducted a detailed process analysis of a medium-sized textile manufacturer and carried out a simulation study to improve daily production routines on the shop floor. This included the analysis of the heterogeneous production data, the management of missing data and the decision to implement a discrete-event simulation model. The simulation study focused on testing isolated production strategies, identifying potential improvements in terms of organizational processes, detecting data leaks as well as designing a model for discrete-event simulation (DES). As a result, a roadmap to establish a seamlessly integrated hardware and software infrastructure was derived. This consists of a catalogue of best practices for lean production as well as an increased level of digitalization on the shop floor and considers the current state of digitalization of the company. © 2023, The Author(s), under exclusive license to Springer Nature Switzerland AG.

关键词： Textile industry

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Integration of Digitization and Sustainability Objectives in a Maturity Model-Based Strategy Development Process 18th

Integration of Digitization and Sustainability Objectives in...

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18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Münnich, Marc Stange, Maximilian Süße, Marian Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

ISBN: (纸本)9783031288388

Political, technological and economic changes force manufacturing companies to shift their strategic alignment towards green and digitized technologies. The parallel advances in those technologies raise questions regarding economic, environmental and social sustainability issues that are challenging to integrate into corporate strategy. Recently, sustainable energy supply has gained additional attention as a critical resource for production. Digital transformation is a diverse intracompany process and requires adequate strategies. Maturity models are a well-known and established approach to define strategic improvement measures. Various versions of separate maturity models to either examine the current state of digitization or sustainability have been developed and there are few models to support both dimensions adequately. Therefore, the authors propose a strategy development process, which utilizes a combined maturity model for both domains in one framework. A review on sustainability-related maturity models as well as the connection to digitization aspects is conducted. Based on this, an existing model is extended. The model is tested in a case study to compare the impact of the models’ adaptions. © 2023, The Author(s).

关键词： Sustainable development

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Topology optimization of nonlinear elastomer engine mounts considering the transfer behavior

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Forschung im Ingenieurwesen 2025年第1期89卷 1-10页

作者： Bahr, S. Jacobs, G. Höpfner, G. Hensel, E. Troge, J. Rapp, T. Institute for Machine Elements and Systems Engineering RWTH Aachen Aachen Germany Institute for Machine Tools and Forming Technology Fraunhofer Dresden Germany

Increasing global competition among electric vehicle manufacturers has elevated the Noise, Vibration, and Harshness (NVH) properties of drivetrains to a key quality feature. Unfavorable NVH properties occur when the drivetrain’s dynamic excitation forces excite modes of the sound-transmitting components at the respective eigenfrequencies. An established strategy to avoid this unwanted NVH behavior is topology optimization (TO), as it can shift unwanted modes of the drivetrain out of the excitation frequency range through geometrical adaptations using finite-element (FE) simulation. Another way to significantly influence unwanted NVH behavior in electric vehicle drivetrains are elastomer engine mounts which are employed to isolate the engine’s vibrations from the surrounding system and to dissipate vibrational energy. However, the effectiveness of these functionalities is limited in frequency ranges of local elastomer modes. Despite TO being well-established, challenges are given in shifting elastomer modes due to the complex material behavior. Firstly, the material’s softness results in an uncontrollably high density of local mount modes for TO, which presents a challenge in developing engine mounts without modes in the drivetrain’s excitation range, especially for electrified engines. Secondly, the elastomer’s nonlinear material impedes calculating the component’s modes with a linearized material approach. The goal of this contribution therefore is to develop a method that considers the complex material behavior of engine mounts in a TO process. To achieve this goal, the ideal transfer behavior of the engine mount, and consequently the positioning of mount modes within the frequency range, is determined based on the sound-transmitting structure and used as an objective for the optimization process. To consider the elastomer’s nonlinear transfer behavior during optimization, material parameters for each considered frequency are applied. The

关键词： Shape optimization

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Simulation of geometrical errors during application of a confocal sensor system for the measurement of large components with high aspect ratios 15

Simulation of geometrical errors during application of a con...

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15th International Conference and Exhibition on Laser Metrology, Coordinate Measuring machine and machine Tool Performance, LAMDAMAP 2023

作者： Teicher, Uwe Gollee, Christian Seidel, André Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Institute of Mechatronic Engineering Technische Universität Dresden Dresden Germany

ISBN: (纸本)9781998999125

Machining of large components for the aerospace industry requires, in addition to sophisticated machining strategies a targeted monitoring of the machining quality due to the enormous demands on precision. For the acquisition of the as-is geometry after single machining steps, a non-contact system based on a confocal chromatic sensor was developed, with whose help the as-is geometry can be compared with the target geometry even in deep cavities at aspect ratios up to 40. The sensor system is coupled with the standard interfaces to a machine tool and performs measuring cycles based on modified NC programs. Data acquisition is done with a control-connected EDGE system. The result of the target/as-is comparison is the basis for CAM planning for subsequent machining. In addition to the design of the measuring system and the integration into the ecosystem of the machine system, a concept to calibrate the measuring system for operation on the machine tool was developed. Based on a simulation model of the measurement system various aspects of the calibration approach were analysed. © euspen Headquarters March 2023.

关键词： Geometry

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Method for Evaluating and Identifying Energy-Efficient Process Chains for the Manufacturing of Press Hardening tools Based on the Deming Circle 18th

Method for Evaluating and Identifying Energy-Efficient Proce...

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18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Rautenstrauch, Anja Markov, Larisa Kräusel, Verena Faculty of Mechanical Engineering Institute for Machine Tools and Production Processes Professorship for Forming and Joining Technische Universitaet Chemnitz Reichenhainer Str.70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany

ISBN: (纸本)9783031288388

In response to rising energy demand, climate change and resource scarcity, the German government has set guiding targets for the transformation of energy systems by 2050. One goal is to increase energy efficiency in order to halve the demand for energy. An important instrument for increasing energy efficiency and reducing energy costs is the energy audit. By determining how much energy is consumed in which areas of the company, it is possible to identify where there is potential for savings. This paper presents an evaluation method for identifying energy-efficient process chains for the production of press hardening tools. The evaluation method is based on the Deming Circle and is intended to serve as a supporting tool for the energy audit. The method enables the analysis and evaluation of energetic variables of a process chain and is designed for manufacturing companies. © 2023, The Author(s).

关键词： Energy utilization

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Component reuse strategy (CRS) for continuous reinforced thermo-sets enabling circular economy

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Journal of Remanufacturing 2022年第3期12卷 339-355页

作者： von Freeden, Justus Husemann, Alexander Caba, Stefan Fraunhofer Institute or Machine Tools and Forming Technology Chemnitz Germany EDAG Engineering GmbH Fulda Germany

A circular economy, effective technologies for the recycling and reuse of fiber-reinforced plastics (FRPs) are essential to keep these materials attractive for use in various products against the backdrop of stricter environmental regulations. This paper provides an overview of the current state of the art in the recycling and reuse of end-of-life (EOL) fiber reinforced plastic (FRP) products. A significant proportion of EOL FRP products are thermally recycled or used as fillers in the cement industry. Complementary to the existing approaches of structural reuse of FRP is presented in this paper as component reuse strategies (CRS). Both approaches avoid separation or destruction (downgrading) of the composite materials. An application example for the reuse of a carbon-fiber reinforced plastics (CFRP) base frame of an electric vehicle platform is given and analyzed with respect to known design for reuse approaches. The proposed CRS has great potential to complement existing approaches and slow down resource consumption. In addition, extended service life can make CFRP materials more economically attractive. However, further developments are needed as well as the transfer of the principle to other applications. © 2022, The Author(s).

关键词： Automotive Carbon fiber Circular economy Design for reuse Fiber reinforced plastics

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Memory Adaptive and Spatially Specialized Model Ensembles for Industrial Anomaly Detection 27

Memory Adaptive and Spatially Specialized Model Ensembles fo...

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27th European Conference on Artificial Intelligence, ECAI 2024

作者： Wagenstetter, Marco Landerer, Niklas Thyroff, Johannes Aicher, Thomas Hellmich, Arvid Ihlenfeldt, Steffen Powertrain Production System Planning BMW Group Germany School of Computation Information and Technology Technical University of Munich Germany Institute for Machine Tools and Forming Technology Fraunhofer IWU Germany

ISBN: (纸本)9781643685489

Industrial anomaly detection models proved to be a viable solution for automating the task of visual inspection. Despite their effectiveness, the deployment of current deep learning models for anomaly detection for high-resolution images involves large memory requirements, which are unattainable in industrial deployments on edge devices. In this paper we introduce a tiling approach for a memory bank based feature embedding model to reduce the memory requirements during training and inference. Additionally, we analyze the correlations between image size, dataset size and required memory. To evaluate the detection performance of different tiling schemes, we create and apply a real industrial training and validation dataset collected in the electric motor housing production of the BMW Group. Our experiments show that depending on the tiling scheme the overall required memory can be decreased by a factor of 12 while leaving the detection performance unchanged and even increase the detection performance when the memory requirement is only halved. This venture underscores the viability of our tiling approach in real-world industrial applications but also marks a significant leap towards resolving the issue of resolution limitations in deploying advanced anomaly detection models. © 2024 The Authors.

关键词： Anomaly detection

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Adhesion Reduction in Plastics Processing by means of laser-generated Microstructuring

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Procedia CIRP 2024年 125卷 130-135页

作者： Eric Gärtner Justus von Freeden Michael Schreiter Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 09126 Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Hermann-Münch-Strasse 2 38440 Wolfsburg Germany

Almost all production processes for manufacturing plastic or fiber reinforced plastic (FRP) components have in common that plastic and a steel surface are pressed together in the process. To avoid adhesion, the steel belts are coated with polytetrafluoroethylene (PTFE), ceramics or perfluoroalkoxy (PFA) during calendering, for example. However, the high temperatures of over 250 °C and the alternating mechanical load lead to damage of the coating. This results in adhesion of the coating to the product and loosening of the coating. Due to this, the surface quality of the organic sheets is reduced, and the production process is negatively affected. As the surface function can be controlled by material and surface patterns with different length scales (nm - µm), the surface topography of the belt steel was specifically modified in the roughness and microstructure level in order to reduce the adhesive interaction with the organic sheet. These microstructures were tested in extensive experiments and the results will be presented in this publication. True to the motto from nature to innovation, the micro- and nanostructured surface of the lotus leaf, which is provided with a fine substructure, was used as reference. The aim was to generate such a hierarchical structure by means of direct laser writing in order to avoid adhesions on production surfaces and to substitute the coating of steel strip surfaces. Additionally, a testing method close to the process was developed and evaluated to test the laser structured microstructures, which will also be presented.

关键词： adhesion reduction laser microstruturing surface functionalisation calendering

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Tool-holder integrated printed piezoceramic sensors for process state classification and tool-wear progress evaluation in turning 20

Tool-holder integrated printed piezoceramic sensors for proc...

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

作者： Panesso, Miguel Berthold, Jan Hamm, Lucas Li, Zongshuo Drossel, Welf-Guntram Bergs, Thomas Fraunhofer Institute for Machine Tools and Forming Technology Nöthnitzer Str. 44 Dresden01187 Germany RWTH Aachen University Campus-Boulevard 30 Aachen52074 Germany

Tool condition monitoring strategies in turning processes, using multiple sensor sources to measure dynamic quantities (e.g., force, acoustic emissions, acceleration), has gained significant attention in conjunction with machine learning methods. As a novel approach, the introduction of printed piezoceramic thick films in machine tools allows the customization of sensor shape and placement, optimized to fit the tool holder's geometry and process boundary conditions. This work proposes integration concepts using two configurations of printed piezoceramic sensors. This includes the use of a finite element simulation to estimate the generated electric charge from sensors on three locations on the tool holder, induced by transient mechanical loading. The design is validated under controlled mechanical loading and tested across various cutting conditions and tool-wear states. Signal information content from each sensor location, relative to different machining conditions, is assessed through recursive feature elimination and validated using dimensionality reduction. Finally, tool-wear progress is evaluated using the selected features. © 2025 The Author(s).

关键词： Thick films

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