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56th CIRP International Conference on Manufacturing Systems, CIRP CMS 2023

作者： Alaluss, Mohaned Kurth, Robin Mauersberger, Anton Drechsler, Chris Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Institute of Mechatronic Engineering Dresden University of Technology Helmholtzstr. 7a Dresden01069 Germany

Rising demands on manufacturing technologies lead to an increase in the complexity of corresponding machines and systems. This complexity acts as an obstacle to the development and realization of digital, usage-based business models for complex manufacturing systems. Particularly in the case of pay-per-use business models, it is necessary to monitor the actual machine load in operation to minimize the business risk on the operator and supplier side. This complicates the transition towards data-oriented value creation in manufacturing system environment. To overcome this challenge, a novel method to assess machine components regarding their potential to monitor the actual load and usage behavior of the whole manufacturing system is proposed. On this basis, the transparency and therefore confidence in digital, usage-based value creation like pay-per-use business models can be increased. The resulting approach is demonstrated by taking the example of a sheet metal forming press. © 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) Peer-review under responsibility of the scientific committee of the 56th CIRP International Conference on Manufacturing Systems 2023.

关键词： Decision making Forning Manufacturing Methodology Service

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Structure and Validation of a Kinematic Surface Simulation Model for the ultrashort-pulse Direct-Laser-Writing Process

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Procedia CIRP 2025年 133卷 227-232页

作者： Fabian Wieland Eric Gärtner Sebastian Wieland Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Functional Surfaces and Micromanufacturing Reichenhainer Str. 88 Chemnitz 09126 Germany

This paper presents the development and validation of a kinematic surface simulation model for the prediction of ultrashort-pulsed laser structured surfaces. The simulation is based on an existing kinematic simulation model for short-pulsed laser structuring and utilizes the stepwise Boolean intersection of a machined and digitized single point ablation with the workpiece to reproduce the microstructuring process. The existing short-pulse simulation model was extended by newly integrated description models to allow a more detailed representation of within the process changing influences, e.g. the surface fine-structure to enable a multi-layer processing. In addition, a reorganization of the simulation algorithm resulted in a general improvement of the run time and a resolution-independence. Based on the kinematic simulation principle, the manufacturing process for a wide range of material-machine combinations in the field of laser structuring can be described. The model enables a time-efficient, nanometer-resolved prediction of representative surfaces with a size of up to several square millimeters. Furthermore, complex influences such as material- and temperature-related properties do not need to be considered separately, as they are taken into account by the machined and digitized single point ablation. Compared to artificial intelligence approaches and numerical or multiphysical simulations, the need for preliminary studies is very low. Depending on the chosen laser machining parameters the simulation can reproduce the surface textures macro- and microstructure.

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Efficient evaluation of the acoustical behavior of gearboxes with various gear blanks using frequency based substructuring 27

Efficient evaluation of the acoustical behavior of gearboxes...

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27th International Congress on Sound and Vibration, ICSV 2021

作者： Hensel, Eric Bräunig, Jan Troge, Jan Stapf, Tom Drossel, Welf-Guntram Fraunhofer Institute for Machine Tools and Forming Technology Dresden Germany

ISBN: (纸本)9788378807995

In several industrial branches, the acoustical behavior of gearboxes plays a major role. In most cases, the transmission's noise is perceived as an annoying sound, the so-called gear whine with narrow-band spectral components. This tonal noise is caused by the gear mesh and is mainly dependent on the number of teeth as well as the corresponding rotational speed. In combination with the frequency-dependent structure-borne and airborne sound transfer paths of the gearbox and its subsequent systems, different speeds may lead to resonant system response due to the variable excitation frequencies. The purpose within the design process of gearboxes is the identification of such critical acoustic load conditions and the deviation of adequate measures to improve the acoustical behavior. As well known from other applications, the frequency based substructuring provides a methodology to evaluate the vibrations of a system consisting of different subsystems represented by frequency-dependent admittance functions. A main advantage of this method is that the single subsystems are independent from the mounting conditions. Within the present paper, the frequency based substructuring approach is used to evaluate the dynamic behavior of a single-stage gearbox with different gear blanks but equal tooth geometries. After a short introduction of the corresponding theory, the application of the frequency based substructuring method on gearbox dynamics is shown. In a next step, the simulation results are compared to experimental data obtained by test bench measurements with two different types of blanks - a reference model with no modifications as well as a gear with a metal foam core to change the stiffness of the gear blank significantly. Finally, the influences of different gear blanks are shown and discussed based on simulation results. © "Advances in Acoustics, Noise and Vibration - 2021" Proceedings of the 27th International Congress on Sound and Vibration, ICSV 2021. All rights re

关键词： Metals

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Software support for the development of flexible plant technology in highly automated and high-rate body-in-white production 16

Software support for the development of flexible plant techn...

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

作者： Fritzsche, Rayk Ahrens, Antje Hd. of Grp. Adaptable Assembly Syst. at Fraunhofer Inst. for Mach. Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany Scientific Employee at Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

The remarkly high degree of automation within body-in-white production, with high quality requirements and the increasing demand for product-flexible production form a conflict of objectives. The most significant challenges in making the operating resources of body-in-white manufacturing more flexible arise with the the development of model-flexible geometry fixtures, with the geometric and qualitative requirements being most significant in the production of vehicle doors. For the efficient design of model-flexible fixtures specific methods and software tools for part alignment, clamp point grouping and fixture design have been developed. © 2023 Elsevier B.V.. All rights reserved.

关键词： Product design

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Electrochemical material removal characteristics of a NdFeB permanent magnet 22

Electrochemical material removal characteristics of a NdFeB ...

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

作者： Petzold, Tom Martin, André Schubert, Andreas Chemnitz University of Technology Institute for Machine Tools and Production Processes Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9781998999118

Electric motors are used in various fields with an ever-increasing demand. In the electromobility sector as an example, a growth of a few hundred thousand motors per year is stated. In many cases, the rotor magnets for electric drives are produced by sintering. Special drives for two-axes positioning with precise movements require individual geometries of the rotor magnets such as spherical shapes. In this case, post-processing of the usually cylindrical or rectangular block shaped bar magnets is necessary. One common technique for post-processing is electrical discharge machining (EDM), which allows the machinability of hard or brittle materials, but also causes thermal impacts, which influence the magnetic properties of the material in a negative way. To overcome this negative effect it is necessary to re-magnetize the rotor magnets after EDM. Additional measurements of the magnetic field strength are required to ensure correct values. Electrochemical machining (ECM) represents an alternative technique for post-processing of rotor magnets, since it offers the possibility to avoid re-magnetization after the shaping process, because machining temperatures are well below the Curie temperature of most materials. In this study, ECM of a NdFeB permanent-magnetic material is presented. The experiments were carried out according to DIN-SPEC 91399. The material-specific removal characteristics indicate an active dissolution with the chosen machining parameters. Comparative measurements of the magnetic field strength before and after ECM indicate that there is no negative influence of the removal process. The results suggest that ECM with pulsed current and oscillating tool cathode is an applicable technique for shaping rotor magnets. © European Society for Precision Engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Neodymium alloys

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Concentric jet for confined mask-less anodic dissolution and oxidation of aluminium 23

Concentric jet for confined mask-less anodic dissolution and...

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23rd International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2023

作者： Martin, André Quitzke, Susanne Morgenstern, Roy Schubert, Andreas Lampke, Thomas Chemnitz University of Technology Institute for Machine Tools and Production Processes Professorship Micromanufacturing Technology Reichenhainer Str. 70 Chemnitz09126 Germany Chemnitz University of Technology Institute of Materials Science and Engineering Materials and Surface Engineering Erfenschlager Str. 73 Chemnitz09125 Germany Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

ISBN: (纸本)9781998999132

Anodic oxide layers are established for wear and corrosion protection of surfaces of aluminium parts and for decoration purposes. Usually, anodizing is carried out in large scale on the whole part surface or locally by masking through immersion in an electrolytic bath. Applying a free jet of electrolyte offers laterally confined anodizing without extensive efforts for masking and enables local functionalization without undesired influence on the surrounding surfaces in a resource- and energy-efficient process. However, the high ohmic resistance of anodic oxides leads to a wide distribution of the current density hindering laterally confined anodizing. More sharp-contoured anodic oxides are aspired through dilution of the electrolyte film flowing off laterally from the aluminium surface. For this purpose, a concentric arrangement of an electrolyte jet surrounded by a jet of deionized water was realized. Investigations on the distribution of electric current density were carried out by electrochemical machining experiments (Jet-ECM). The application of an actively anodic dissolving electrolyte of NaCl indicates the widening of the current density distribution in terms of pitting corrosion. Compared to the free electrolyte jet surrounded by atmospheric air, a wider current density distribution was detected when applying a concentric jet of deionized water. But the shape of the dissolved cavities was not widened, which indicates only low current density values on the surrounding surface. Verification experiments on anodization confirm the comparably strong localization of anodic oxides with concentric jet and an increase in thickness compared to the results with free electrolytic jet. It was found that this is mainly because of the high ohmic resistance of the anodic oxide formed on the surrounding surface and its increasing resistance at farther lateral distance from the jet due to stronger electrolyte dilution. © 2023 Euspen Headquarters.

关键词： Electrolytes

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Identifying efficiency and flexibility measures for energy-oriented factory management 29

Identifying efficiency and flexibility measures for energy-o...

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29th CIRP Conference on Life Cycle Engineering, LCE 2022

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

Recent efforts in climate politics increase the ecological pressure of manufacturing companies in terms of intelligent and efficient usage of resources during operations. Rising energy prices lead to further economic pressure. Especially companies with a high share of energy cost on total costs are forced to continuously improve processes regarding the energy usage. Existing guidelines and methodologies are usually concerned with either of the two dimensions energy efficiency (EnEff), or energy flexibility (EnFlex). While EnEff addresses the reduction of the energy consumption for a defined manufacturing output, EnFlex addresses the advantageous shift, increase, and decrease of energy demand. Although both dimensions address the total reduction of cost, they are usually considered separately in literature. Here, we examine both dimensions while focusing on the provision and usage of electric energy due to its manifold conversion and usability opportunities in factory processes. Therefore, we developed an overview of measures of both dimensions as well as their application characteristics within the factory. To identify EnEff and EnFlex measures, a practicable methodology is introduced. This aims to enable especially companies with few experiences in EnEff and EnFlex measure application to improve energy aware operations. We illustrate our examination by means of an industrial application example. © 2022 Elsevier B.V.. All rights reserved.

关键词： Energy efficiency

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A survey on smart product-service systems in manufacturing

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Procedia CIRP 2023年 120卷 1504-1509页

作者： Anton Mauersberger Mohaned Alaluss Antonia Beyer Kilian Armin Nölscher Alexander Rauscher Heiner Reinhardt Steffen Ihlenfeldt Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 09126 Chemnitz Germany

The advancing digitization affects product design and manufacturing. Companies focus on product-service systems (PSS) to improve customer satisfaction and loyalty. However, these PSS become increasingly complex as digital technologies are incorporated and cross-company collaboration and manufacturing is facilitated. In essence, we can observe a transition from conventional PSS to smart PSS, where the opportunities of digitization are effectively utilized and synergies between multiple stakeholders are fostered. Here, we present an analysis and classification of smart PSS considering aspects of business modeling, composition, design, quality and sustainability.

关键词： Smart PSS Smart service Smart technologies Product-service system Remote service Development Innovation management Production Modular design Decision making

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Dismantling and remanufacturing strategies in the automotive sector

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Procedia CIRP 2024年 122卷 695-700页

作者： Rico Haase Daniele Farioli Rene Selbmann Markus Werner Verena Kräusel Fraunhofer Institute for Machine Tools and Forming Technology 09126 Chemnitz Germany Politecnico di Milano Department of Mechanical Engineering 20156 Milan Italy

The contemporary recycling of automobiles takes place on a very baseline material level. In order to fundamentally improve the ecologic footprint of the vehicle, a wider application of remanufacturing strategies is intended. Following different recycling approaches ranging from direct reuse or refurbishment through remanufacturing until repurpose, a well-aimed dismantling followed by manufacturing processes adapted to the post-consumer components is mandatorily required. For use on an industrial scale, environmental efficiency and economic viability must be balanced well. Within the paper, possible remanufacturing technologies and necessary prerequisites such as input data are discussed. For the design of remanufacturing operations, material properties and geometric information are a crucial starting point. Seamless integration of the specific properties is intended to encourage wider utilization of pre-used components and materials. With reference to the well-established process design for metal forming operations, adapted material cards and curvature equivalence values are proposed. The approach is illustrated by a reforming operation, where a brake disc cover is remanufactured from a used car body roof.

关键词： circular economy automotive recycling dismantling remanufacturing secondary raw material pre-used components

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A survey on sustainability approaches in manufacturing 30

A survey on sustainability approaches in manufacturing

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30th CIRP Life Cycle Engineering Conference, LCE 2023

作者： Prell, Bastian Reinhardt, Heiner Mauersberger, Anton Rauscher, Alexander Reiff-Stephan, Jörg Ihlenfeldt, Steffen Technical University of Applied Sciences Wildau Hochschulring 1 Wildau15745 Germany Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Awareness about climate change has led to policies and regulations but also customer preferences favoring sustainable production. Thus, producing businesses are confronted by this, as they consume a large share of resources. Therefore, when producing, additional dimensions beyond commercial feasibility ought to be considered. Here, literature on sustainability from the field of engineering science is systematically searched and analyzed for approaches leading to actual recommendations for action. Hence, this bottom-up approach, incorporating the production engineers' point of view, represents an inside view of how the topic of sustainability has arrived at production companies. The focus on commercial feasibility ensures high relevance to practice, as production needs to become both sustainable and competitive. Even though exemplary collections of different approaches addressing the topic of sustainability in production can be found in literature, novelty is provided by the structured manner literature was collected and the special focus on approaches leading to practice-relevant recommendations for action. Thus, a comprehensive overview of approaches applicable to the manufacturing domain is presented. © 2023 The Authors. Published by Elsevier B.V.

关键词： Sustainable development

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