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Potential of Radar Based Measuring Systems in Hot Forging 18th

Potential of Radar Based Measuring Systems in Hot Forging

引用

18th Global Conference on Sustainable Manufacturing, GCSM 2022

作者： Bergmann, M. Dix, M. Wallbaum, T. Selbmannn, R. Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Straße 88 Chemnitz09126 Germany Institute for Machine Tools and Production Processes Chemnitz University of Technology Chemnitz09126 Germany

ISBN: (纸本)9783031288388

Hot forging processes and process chains provide components, which meet highest demands due to mechanical properties. A wide range of applications in different industries like oil and gas, automotive and aviation are based on such processes. As those processes are very productive unfavorable process conditions and unnecessary reject or rework are a strong issues and still not solved for industrial scale production. One key challenge is to generate geometrical information of the workpiece. The geometrical characterization of hot forged parts is usually carried out in cold condition resulting in an extensive time delay to processing. Information about the part geometry during processing and right after processing – in hot condition -- is not accessible. An approach to address this are radar based measuring systems. Those systems have specific characteristics like sufficient accuracy and robustness which qualifies them for measuring tasks under rough conditions typically occurring during forging processes. In the paper, different use cases for the application of radar-based measuring systems are identified and analyses based on laboratory scale experiments. © 2023, The Author(s).

关键词： Radar measurement

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Structure and Validation of a Kinematic Surface Simulation Model for the ultrashort-pulse Direct-Laser-Writing Process 20

Structure and Validation of a Kinematic Surface Simulation M...

引用

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

作者： Wieland, Fabian Gärtner, Eric Wieland, Sebastian Fraunhofer Institute for Machine Tools and Forming Technology IWU Department Functional Surfaces and Micromanufacturing Reichenhainer Str. 88 Chemnitz09126 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. © 2025 Elsevier B.V.. All rights reserved.

关键词： Kinematics

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Virtual sensor for monitoring the geometric and kinematic accuracy of machine tools 19

Virtual sensor for monitoring the geometric and kinematic ac...

引用

19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Doerrer, Felix Otto, Andreas Kolouch, Martin Rentzsch, Hendrik Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology Reichenhainer Str. 88 Chemnitz09126 Germany

The performance of machine tools depends on their working accuracy. The paper presents a new approach for in-process monitoring the geometric and kinematic accuracy of a machine tools. This approach utilizes a virtual sensor for capturing displacements at the tool center point (TCP). The virtual sensor is set up by using a data-driven approach based on extended transmissibility functions. The input data for monitoring are the NC internal data. The transmissibility functions are established via standard experimental procedures such as double ball bar (DBB) tests tests and estimation of frequency response functions (FRF). The data from the virtual sensor can be used for process monitoring and troubleshooting when launching a new process. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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Data preparation for AI-based robot control 16

Data preparation for AI-based robot control

引用

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

作者： Abdolmohammadi, Tina Ahrens, Antje Richter-Trummer, Valentin Todtermuschke, Marcel Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Strasse 88 Chemnitz09126 Germany

Roll-profiling is traditionally used for low-cost, high-volume manufacturing. However, complex sheet metal parts usually require labor-intensive forming processes, including post-forming straightening processes, to achieve optimal tolerances, thus increasing cost. Robotic roll-profiling already paves the way for single-part manufacturing. The current work focuses on developing the foundations for AI-based control strategies for in-line straightening, eliminating the need for post-forming straightening processes. Reaction forces and torques on the forming tool were analyzed and compared to part geometry reference measurements. Data processing and evaluation were developed, and different regression algorithms and neural networks were compared. © 2023 Elsevier B.V.. All rights reserved.

关键词： Data handling

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Manufacturing of complex NiTi geometries with LPBF and adapted scanning strategies

Manufacturing of complex NiTi geometries with LPBF and adapt...

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2024 International Conference on Shape Memory and Superelastic Technologies, SMST 2024

作者： Herzig, Sandra Eckert, Medardus Müller, Bernhard Weisheit, Linda Thielsch, Juliane Drossel, Welf-Guntram Holtzhausen, Stefan Koch, Peter Schleyer, Mario Fraunhofer Institute for Machine Tools and Forming Technology IWU Dresden Germany Dresden University of Technology Dresden Germany Fraunhofer Institute for Mechanics of Materials IWM Freiburg Germany

ISBN: (纸本)9781627084840

NiTi shows a very promising combination of properties among different shape memory alloys. However, machining NiTi is a challenging task, making the manufacturing of complex geometries hard to nearly impossible using conventional manufacturing routes. As a result, the material’s full potential of the material has not been harnessed. The pseudoelastic properties of bulk NiTi are restricted to an 8 % strain [1]. Additive manufacturing of NiTi using laser powder bed fusion (LPBF) has been demonstrated as a successful alternative production route [2], capable of exhibiting pseudoelastic behavior even in the as-built state [3]. Existing literature has shown that modifications of the processing parameters can change the properties of Ni-rich NiTi significantly [4], which can be utilized intentionally to control the pseudoelastic properties in LPBF-manufactured NiTi. The fabrication of porous and lattice structures using LPBF allows to attain specific properties. This is achieved not only through the adjustment of the laser parameters and scanning pattern but also by enabling the creation of specifically tailored feature sizes and geometrical designs, such as unit cell design, the number and distribution of unit cells, and gradation. These geometrical structures go beyond the conventional unit cell designs (like the bcc unit cell), and when combined with the unique material behavior, they can result in extraordinary properties. It is possible to create a programmable material whose behavior can follow a logical description. The influence of lattice structure geometry and manufacturing parameters on the mechanical and functional performance will be discussed in the following. In addition, we present a structure whose stiffness behavior follows an if-then-else statement regarding to the effective strain and permits an effective strain exceeding 20 % without failure. The structure can be implemented in a planar clamping element which allows an adjustment to different shapes b

关键词： Titanium alloys

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Experimental setup for long term high-precision static friction tests for clamping systems of rotary tables in cutting machine tools 23

Experimental setup for long term high-precision static frict...

引用

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

作者： Wieland, Sebastian Zschech, Richard Schneider, Jörg Müller, Jens Edelmann, Jan Fraunhofer Institute for Machine Tools and Forming Technology IWU Chemnitz Germany Dresden University of Technology Institute Of Mechatronic Engineering Dresden Germany

ISBN: (纸本)9781998999132

The objective of the scientific investigation is the determination of the coefficient of static friction for clamping systems of rotary tables in cutting machine tools. New developments in this field of research are able to lead to an enhancement in tolerable cutting forces and machine accuracy or to the minimization of the required clamping forces and the constructed space too. In this context the requirement profile of the investigated clamping systems is more than complex. Since they have an immediate influence on the machine accuracy only smallest movements between the friction partners in the range of a few micrometres are tolerable. Furthermore a clamping system needs to withstand more than 100,000 clamping cycles and also braking applications in case of emergency. Against this background an experimental setup consisting of two testing benches was developed. The first testing bench offers the possibility of quick measurements of the coefficient of static friction by a linear movement to investigate a high number of different samples for a selection process. The second test bench in addition offers the possibility of testing the relevant samples by a torsional load for more than 100,000 clamping cycles and in braking applications. In a study the two test benches are validated and compared against each other based on a state of the art clamping system of a tempered steel on the basis of the determined coefficients of static friction. In addition the results of the long term friction experiments and the observed wear are discussed. © 2023 Euspen Headquarters.

关键词： Wear of materials

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Modeling of tool load for optimization of tool life in diagonal generating grinding 19

Modeling of tool load for optimization of tool life in diago...

引用

19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Rößler, Maximilian Krage, Robin Dix, Martin Fraunhofer-Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 Germany

Diagonal continuous generating grinding with ceramic bonded wheels is commonly used for hard finishing of automotive gears with topological modifications. In this process, areas of the grinding wheel have to be used repeatedly to machine multiple components, resulting in not achieving the same tool life as conventional generating grinding. This paper presents a detailed process model predicting loads on the wheel as a basis for an optimization of tool life. Based on a redistribution of the roughing and shifting areas of the grinding wheel, significantly lower wear could be demonstrated in tests. © 2023 Elsevier B.V.. All rights reserved.

关键词： Grinding (machining)

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Simulation tool for chatter prediction of varying tool-machine configurations based on dynamic substructuring 19

Simulation tool for chatter prediction of varying tool-machi...

引用

19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Schuster, Alexander Sahu, Govind N. Rentzsch, Hendrik Otto, Andreas Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Str. 88 Chemnitz09126 Germany

Cutting tools of different type, shape and size are used in milling processes. Every individual tool changes the dynamic behavior of the system and results in varying occurrences of chatter vibrations. This paper presents a simulation tool using a frequency based substructuring method for predicting the process stability without separate measurements of the tool-machine configuration. In particular, frequency response functions of any combined tool-machine configuration is synthesized by the receptance coupling substructure analysis. It enables the calculation of critical machining parameters and maximizing material removal rates by avoiding unstable cutting conditions. Verification is done via finite element analysis of exemplary tool and machine structures. © 2023 Elsevier B.V.. All rights reserved.

关键词： machine tools

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Joining of Laminated Core and Shaft of an Electric machine Rotor by Electromagnetic forming

Joining of Laminated Core and Shaft of an Electric Machine R...

引用

International Electric Drives Production Conference (EDPC)

作者： Verena Psyk Linda Fleischer Maik Linnemann Mirko Bach Martin Dix Department Forming Technology Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz Germany

ISBN: (数字)9798350356885

ISBN: (纸本)9798350356892

In the mobility industry and especially in case of electrically powered vehicles the implementation of lightweight powertrain components with high efficiency and minimum in-stallation space is of utmost importance. One approach to realize a particularly compact and light design is using a central motor, which is aligned with a planetary gearbox via coaxial (partly) hollow rotor shafts positioned one within the other to operate the left and right-hand wheels of the car. To enable further weight reduction, aluminium alloys might be considered for the hollow shafts instead of the conventionally used steel. When the electrical machine is assembled, the shafts must be firmly connected to the rotor core, which is typically made of laminated electrical steel core. Electromagnetic forming is a promising technology for joining tubular aluminium components with similar or dissimilar materials. In this paper, the suitability for the described joining task is investigated. For this purpose, an inductor specifically suitable for expanding a round tube into a non-rotationally symmetric cross section shape is suggested and the corresponding joining process is developed using coupled electromagnetic and structural mechanical simulation. Experimental validation is carried out using a technology demonstrator.

关键词： Shafts Space vehicles Shape Rotors Wheels Mechanical power transmission Topology Steel Electromagnetics Joining processes

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A survey on smart product-service systems in manufacturing 56

A survey on smart product-service systems in manufacturing

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

作者： Mauersberger, Anton Alaluss, Mohaned Beyer, Antonia Nölscher, Kilian Armin Rauscher, Alexander Reinhardt, Heiner Ihlenfeldt, Steffen Fraunhofer Institute for Machine Tools and Forming Technology IWU Reichenhainer Straße 88 Chemnitz09126 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. © 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 Development Innovation management Modular design Product-service system Production Remote service Smart PSS Smart service Smart technologies

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