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In the early-stage development of sheet metal parts, key design properties of new structures must be specified. As these decisions are made under significant uncertainty regarding drawing configuration changes, they sometimes result in the development of new parts that, at a later design stage, will not be drawable. As a result, there is a need to increase the certainty of experience-driven drawing configuration decisions.
Complementing this process with a global sensitivity analysis can provide insight into the impact of various changes in drawing configurations on drawability, unveiling cost-effective strategies to ensure the drawability of new parts. However, when quantitative global sensitivity approaches, such as Sobol's method, are utilized, the computational requirements for obtaining Sobol indices can become prohibitive even for small application problems. To circumvent computational limitations, we evaluate the applicability of different surrogate models engaged in computing global design variable sensitivities for the drawability assessment of a deep-drawn component.
Here, we show in an exemplary application problem, that both a standard kriging model and an ensemble model can provide commendable results at a fraction of the computational cost. Moreover, we compare our surrogate models to existing approaches in the field. Furthermore, we show that the error introduced by the surrogate models is of the same order of magnitude as that from the choice of drawability measure. In consequence, our surrogate models can improve the cost-effective development of a component in the early design phase.
AbstractRegularized static friction models have been used successfully for many years. However, they are unable to maintain static friction in detail. For this reason, dynamic friction models have been developed and published in the literature. However, commercial multibody simulation packages such as Adams, RecurDyn, and Simpack have developed their own specific stick-slip models instead of adopting one of the public domain approaches. This article introduces the fundamentals of these commercial models and their behavior from a practical point of view. The stick-slip models were applied to a simple test model and a more sophisticated model of a festoon cable system using their standard parameters.
Test Setup for Investigating the Impact Behavior of Biaxially Prestressed Composite Laminates
(2024)
Instrumented impact testing and compression-after-impact testing are important to adequately qualify material behavior and safely design composite structures. However, the stresses to which fiber-reinforced plastic components are typically subjected in practice are not considered in the impact test methods recommended in guidelines or standards. In this paper, a test setup for investigating the impact behavior of composite specimens under plane uniaxial and biaxial preloading is presented. For this purpose, a special test setup consisting of a biaxial testing machine and a specially designed drop-weight tower was developed. The design decisions were derived from existing guidelines and standards with the aim of inducing barely visible impact damage in laminated carbon fiber-reinforced plastic specimens. Several measurement systems have been integrated into the setup to allow comprehensive observation of the impact event and specimen behavior. A feasibility test was performed with biaxially prestressed carbon fiber-reinforced plastic specimens in comparison with unstressed reference tests. The compressive-tensile prestressing resulted in lower maximum contact forces, higher maximum deflections, higher residual deflections and a different damage pattern, which was investigated by light microscopic analysis. Finally, the functionality of the experimental setup is discussed, and the results seem to indicate that the test setup and parameters were properly chosen to investigate the effect of prestresses on the impacts behavior of composite structures, in particular for barely visible subsequent damages.
The pandemic caused by the SARS-CoV-2 virus has claimed more than 6.5 million lives worldwide. This global challenge has led to accelerated development of highly effective vaccines tied to their ability to elicit a sustained immune response. While numerous studies have focused primarily on the spike (S) protein, less is known about the interior of the virus. Here we propose a methodology that combines several experimental and simulation techniques to elucidate the internal structure and mechanical properties of the SARS-CoV-2 virus. The mechanical response of the virus was analyzed by nanoindentation tests using a novel flat indenter and evaluated in comparison to a conventional sharp tip indentation. The elastic properties of the viral membrane were estimated by analytical solutions, molecular dynamics (MD) simulations on a membrane patch and by a 3D Finite Element (FE)-beam model of the virion's spike protein and membrane molecular structure. The FE-based inverse engineering approach provided a reasonable reproduction of the mechanical response of the virus from the sharp tip indentation and was successfully verified against the flat tip indentation results. The elastic modulus of the viral membrane was estimated in the range of 7-20 MPa. MD simulations showed that the presence of proteins significantly reduces the fracture strength of the membrane patch. However, FE simulations revealed an overall high fracture strength of the virus, with a mechanical behavior similar to the highly ductile behavior of engineering metallic materials. The failure mechanics of the membrane during sharp tip indentation includes progressive damage combined with localized collapse of the membrane due to severe bending. Furthermore, the results support the hypothesis of a close association of the long membrane proteins (M) with membrane-bound hexagonally packed ribonucleoproteins (RNPs). Beyond improved understanding of coronavirus structure, the present findings offer a knowledge base for the development of novel prevention and treatment methods that are independent of the immune system.
In fatigue strength assessment, the methods based on ideal elastic stresses according to Basquin and the less established method based on elastic-plastic stress quantities according to Manson, Coffin and Morrow are applied. The former calculates loads using linear-elastic stresses, the latter requires elasticplastic evaluation parameters, such as stresses and strains. These can be determined by finite element analysis (FEA) with a linear-elastic constitutive law, and subsequent conversion to elastic-plastic loads, using the macro support formula by Neuber. In this contribution, an alternative approach to approximate elastic-plastic parameters proposed by Glinka is compared to the the strain-life method using Neuber's formula, as well as the stress-life method of Basquin. Several component tests on 42CrMoS4-QT specimens are investigated. To determine the input data for the fatigue strength evaluations, the entire test setup is computed by FEA. The nodal displacements from these validated full-model simulations are used as boundary conditions for a submodel simulation of a notch, whose results serve as input for the fatigue strength assessments. It is shown that all approaches provide a reliable assessment of components. Our key result is that the strain-life method using the concept by Glinka for notch stress computation, yields improved results in fatigue strength assessments.
Although magnesium and its alloys are promising candidates as biodegradable implant materials, the tendency for localized corrosion mechanism in physiological environment limit their biomedical application. Electropolishing is an attractive strategy for improving the corrosion behaviour of metals, but it is still largely unexplored in magnesium materials. In this study, the characterization of electropolished surfaces of AM50 and pure magnesium was performed, focussing on their in vitro degradation behaviour in cell medium. Corrosion rates were evaluated using potentiodynamic polarisation. The surface morphology before and after the onset of corrosion was investigated by scanning electron microscopy and confocal laser scanning microscopy. The presented electropolishing process led to improved surface performances, observable by significantly lower corrosion rates (0.08 mm·year-1 in Dulbecco's modified Eagle's medium), lower arithmetical mean height (0.05 µm), lower water contact angle (25-35°) and lower micro hardness (35-50 HV 0.1) compared to mechanically and chemically treated surfaces. MgO/Mg(OH)2 could be detected on electropolished surfaces. The localized corrosion mode could be reduced, but not entirely prevented. Electropolishing shows great potential as post-treatment of magnesium-based components, but detailed tests of the long-term corrosion behaviour are an important area of future research.
One major goal of production system design is to decide on space requirements in the plant. In this phase, detailed information about the supply chain network (e.g. which suppliers deliver which parts) is often unavailable. Nevertheless, typical decisions in supply chain management, like the definition of replenishment processes and quantities or make-or-buy decisions, impact space requirements and the capital investment in raw materials. Therefore, it should be considered in factory and production planning. This research article proposes a simulation approach for a production simulation in which raw material replenishment is integrated to evaluate the capital investment and space requirements for raw materials.
The present study investigates the interface between carbon steel and titanium samples annealed at different temperatures (𝜗1 = 800 ◦C and 𝜗2 = 1050 ◦C). In both cases, an observable layer forms at the interface, with its thickness increasing from t𝜗1= 2.75 ± 0.15 μm at 800 ◦C to t𝜗2= 8.86 ± 0.29 μm at 1050 ◦C. The layer’s composition and thickness evolve with temperature. Analysis reveals approximately 40 at.-% carbon concentration in the exterior region, indicating likely titanium carbide creation. X-ray diffraction identifies titanium carbide peaks, while microscopy and elemental mapping confirm compositional gradients at the interface.
Electron Backscatter Diffraction (EBSD) shows a gradient in grain size near the TiC surface, reflecting TiC nucleation rates. XRD data detect both titanium carbide and titanium phases, with TiC becoming more prominent at 1050 ◦C. Rietveld analysis further confirms TiC formation. Notably, distinct diffraction patterns on the contact and rear sides suggest a Ti(C, O, N) presence. Depth profiles exhibit varying surface and depth carbon concentrations, attributed to temperature effects. The study successfully demonstrates TiC coating fabrication through hot pressing, wherein Ti(C, O, N) coatings arise from titanium’s affinity for reacting with oxygen and nitrogen. This research contributes to the understanding of phase transformations and interfacial properties in titanium-carbon steel systems.
The low-cycle and high-cycle fatigue behavior of the Mg-base wrought alloy AZ31 is investigated in the temperature range 20– 300 °C using total-strain-controlled push – pull tests. It is shown that the mechanical properties of the material are substantially influenced by the direction dependent formation of deformation twins and resulting deformation asymmetry. As a consequence tensile mean stresses develop during total-strain-controlled fatigue tests without mean strain.
Review of elasto-static models for three-dimensional analysis of thick-walled anisotropic tubes
(2023)
Most shell or beam models of anisotropic tubes under bending have no validity for thick-walled structures. As a result, the need to develop three-dimensional formulations which allow a change in the stress, strain and displacement distributions across the radial component arises. Basic formulations on three-dimensional anisotropic elasticity were made either stressor displacement-based by Lekhnitskii or Stroh on plates. Lekhnitskii also was the first to expand these analytical formulations to tubes under various loading conditions. This paper presents a review of the stress and strain analysis of tube models using three-dimensional anisotropic elasticity. The focus lies on layered structures, like fiber-reinforced plastics, under various bending loads, although the basic formulations and models regarding axisymmetric loads are briefly discussed. One section is also dedicated to the determination of an equivalent bending stiffness of tubes.
LuGre or not LuGre
(2023)
The LuGre model is widely used in the analysis and control of systems with friction. Recently, it has even been made available in the commercial multibody dynamics simulation software system Adams. However, the LuGre model exhibits well-known drawbacks like too low and force rate-dependent break-away forces, drift problems during sticking periods, and significant differences in non-stationary situations between the pre-defined friction law and the one produced by the LuGre model. In the present literature, these problems are supposed to come from the model dynamics or its nonlinear nature. However, most of these drawbacks are not simple side effects of a dynamic friction model but are caused in the LuGre approach, as shown here, by a too simple and inconsistent model of the bristle dynamics. Standard examples and a more practical application demonstrate that the LuGre model is not a “what you see is what you get” approach. A dynamic friction model with accurate bristle dynamics and consistent friction force is set up here. It provides insight into the physical basis of the LuGre model dynamics. However, it results in a nonlinear and implicit differential equation, whose solution will not be easy because of the ambiguity of the friction characteristics. The standard workaround, a static model based on simple regularized characteristics, produces reliable and generally satisfactory results but definitely cannot maintain a stick. The paper presents a second-order dynamic friction model, which may serve as an alternative. It can maintain a stick and produces realistic and reliable results.
Titanium is used in many areas due to its excellent mechanical, biological and corrosion-resistant properties. Implants often have thin and filigree structures, providing an ideal application for fine cutting with laser. In the literature, the main focus is primarily on investigating and optimizing the parameters for titanium sheets with thicknesses greater than 1 mm. Hence, in this study, the basic manufacturing parameters of laser power, cutting speed and laser pulse of a 200 W modulated fiber laser are investigated for 0.15 mm thick grade 2 titanium sheets. A reproducible, continuous cut could be achieved using 90 W laser-power and 2 mm/s cutting-speed. Pulse pause variations between 85 and 335 μs in 50 μs steps and a fixed pulse width of 50 μs show that a minimum kerf width of 23.4 μm, as well as a minimum cut edge roughness Rz of 3.59 μm, is achieved at the lowest pulse pause duration. An increase in roughness towards the laser exit side, independent of the laser pulse pause duration, was found and discussed. The results provide initial process parameters for cutting thin titanium sheets and thus provide the basis for further investigations, such as the influence of cutting gas pressure and composition on the cut edge.
New structural sheet metal parts are developed in an iterative, time-consuming manner. To improve the reproducibility and speed up the iterative drawability assessment, we propose a novel low-dimensional multi-fidelity inspired machine learning architecture. The approach utilizes the results of low-fidelity and high-fidelity finite element deep drawing simulation schemes. It hereby relies not only on parameters, but also on additional features to improve the generalization ability and applicability of the drawability assessment compared to classical approaches. Using the machine learning approach on a generated data set for a wide range of different cross-die drawing configurations, a classifier is trained to distinguish between drawable and non-drawable setups. Furthermore, two regression models, one for drawable and one for non-drawable designs are developed that rank designs by drawability. At instantaneous evaluation time, classification scores of high accuracy as well as regression scores of high quality for both regressors are achieved. The presented models can substitute low-fidelity finite element models due to their low evaluation times while at the same time, their predictive quality is close to high-fidelity models. This approach may enable fast and efficient assessments of designs in early development phases at the accuracy of a later design phase in the future.
Heat staking is a joining technology by which thermoplastic pins are formed by force and temperature to create a form- and force-fitting connection between components. This paper examines the characteristics of 3D printed pins in comparison to conventionally turned pins for heat staking applications. The 3D printed pins are created using fused layer modeling, with variations in horizontal and vertical building directions, as well as different layer thicknesses. The study investigates the impact of significant factors on the heat staking process, including the forming force and temperature. Tensile tests, micrographs, and micro-CT measurements were conducted to determine the properties of the heat-staked joints. Additionally, a stage plan was developed to enhance the understanding of the forming process of both printed and conventionally turned materials. The findings suggest that, under specific process parameters, 3D printed pins exhibit comparable strength to conventionally manufactured pins. The research also demonstrates that the anisotropy resulting from the layer-by-layer construction of the pins significantly influences the strength of the connection. Furthermore, the study reveals that 3D printed pins exhibit good forming accuracy during the heat staking process, and the cavities formed during printing can be substantially reduced.
Kombinationen aus kraft- und formschlüssigen Verbindungen erhöhen die Leistung bei im Hybridguss verbundenen Gussteilen mit Anbau- oder Einlegeteilen und machen separate Fügeprozesse überflüssig. Simulations-Methoden unterstützen das Design kraft- und formschlüssiger Verbindungen. Ergebnisse eines Ausdrückversuchs zeigen eine relativ gute Übereinstimmung zwischen gemessenen und mittels Simulation ermittelten Kraft-Weg-Kurven.
It is well known that mechanical surface treatments, such as deep rolling, shot peening and laser shock peening, can significantly improve the fatigue behavior of highly-stressed metallic components. Deep rolling (DR) is particularly attractive since it is possible to generate, near the surface, deep compressive residual stresses and work hardened layers while retaining a relatively smooth surface finish. In the present investigation, the effect of DR on the low-cycle fatigue (LCF) and high-cycle fatigue (HCF) behavior of a Ti–6Al–4V alloy is examined, with particular emphasis on the thermal and mechanical stability of the residual stress states and the near-surface microstructures. Preliminary results on laser shock peened Ti–6Al–4V are also presented for comparison. Particular emphasis is devoted to the question of whether such surface treatments are effective for improving the fatigue properties at elevated temperatures up to ∼450 °C, i.e. at a homologous temperature of ∼0.4T/Tm (where Tm is the melting temperature). Based on cyclic deformation and stress/life (S/N) fatigue behavior, together with the X-ray diffraction and in situ transmission electron microscopy (TEM) observations of the microstructure, it was found that deep rolling can be quite effective in retarding the initiation and initial propagation of fatigue cracks in Ti–6Al–4V at such higher temperatures, despite the almost complete relaxation of the near-surface residual stresses. In the absence of such stresses, it is shown that the near-surface microstructures, which in Ti–6Al–4V consist of a layer of work hardened nanoscale grains, play a critical role in the enhancement of fatigue life by mechanical surface treatment.
The movement of a meniscus inside a capillary tube has been extensively studied in the context of displacing one fluid with another immiscible one. This phenomenon exists in many applications including pharmaceutical, oil production, filtration and separation processes, and others. When one of the phases is entrapped inside a capillary tube, it forms what is called a ganglion with two menisci between the two fluids. In a straight uniform capillary tube, a stagnant entrapped ganglion is symmetric. The situation is different if the capillary tube is tapered in which case the two menisci assume different curvatures. Such inhomogeneity of the capillary pressure self-propels the ganglion to move. The fate of the ganglion inside the tapered tube depends on whether it is wetting or nonwetting to the tube wall. That is, after the initial movement, a wetting ganglion accelerates towards the tapered end of the tube while a nonwetting one decelerates towards the wider end before reaching a terminal configuration. Such fates are linked to the variations of the capillary pressure, which continuously increases for a wetting ganglion and decreases for the nonwetting one. In this work, a generalized model is developed that not only describes capillary-driven dynamics over a wide range of viscosity and density contrasts but also pressure-driven scenarios with/without gravity. The model, however, neglects the inertial effect of the two fluids on account of the fact that it is confined to the very early time of the movement process. A first-order nonlinear ordinary differential equation is developed that describes the dynamic behavior of both the wetting and nonwetting ganglions. A fourth-order Runge-Kutta algorithm is developed to solve the model equations. Furthermore, a computational fluid dynamics (CFD) analysis was used to provide a comparison and verification framework.
Maintaining dimensional accuracy is a major challenge of laser powder bed fusion (L-PBF) preventing its application for more complex and filigree L-PBF structures in industrial practice. Previous studies have shown that residual stresses and distortion of benchmark L-PBF components may be predicted by sequential thermo-mechanical analyses. However, the reliability of these analyses for more complex structures must be critically questioned, as comprehensive validation and sensitivity analyses are scarce. In this paper, we present a calibrated and validated low-fidelity sequential thermo-mechanical finite element analysis (FEA) of a tubular L-PBF lattice structure, i.e., an aortic stent, where pronounced local deformation is expected. As a first step, the finite element model was extensively calibrated using experimental data to ensure reproducibility of the simulation results. Thereupon, geometric features critical to the distortion of L-PBF lattice structures and measures to compensate for the distortion, such as inversion of the distorted L-PBF structure, were investigated. It was found that the distortion of the L-PBF lattice structures can be reduced, but not completely prevented, by increasing the strut angles, increasing the strut thickness, and decreasing the transition radius in the area of merging struts. FEA-based inversion of the numerically predicted deformed structure minimized distortion, resulting in the L-PBF aortic stent approximating the intended CAD geometry even with a small strut thickness. This work shows that low-fidelity sequential thermo-mechanical FEA can be used not only for the analysis and deformation compensation of reference structures, but also for the analysis of more complex filigree structures with pronounced local deformation.
Additive Manufacturing (AM) is a future-oriented manufacturing technology that is experiencing an enormous boom in the times of Industry 4.0. As a result, various AM technologies and printer models from different manufacturers are entering the market over a short time span. With the advancing establishment of this manufacturing technology for series applications, the expectations and requirements of the fabricated components are also increasing. However, a major challenge is the application-specific selection of the most suitable AM process due to a lack of comparable data. Furthermore, there needs to be more know-how regarding the geometrical and mechanical characteristics of AM parts. This paper addresses this problem by comparing the three most common plasticbased AM processes in the areas of surface quality, dimensional accuracy, and mechanical properties. Roughness measurements, evaluation of a benchmark artifact, tensile tests, and load increase tests are carried out. Based on the results, the individual possibilities and limitations of the compared AM processes can be detected.
Although many composite structures are inconsistently curved, such as the leading edges of aircraft wings, the variety of research in impact engineering is almost limited to the impact performance of plates or cylindrically curved specimens. It is not known whether the findings obtained from standardized tests can be transferred to curved structures or which adaptions are required. Therefore, a deeper understanding of the deformation and damage behavior of inconsistently curved structures is essential to transfer the observed impact behavior of flat specimens to general curved structures and therefore to utilize the full lightweight potential of a load-specific design. An accurate description of the procedure as well as the results of the experimental and numerical study of the low-velocity impact behavior of differently single-curved elliptic specimens is presented. To close the research gap of the impact behavior of geometries with curvatures between the plates and simplified leading edges, novel specimens geometries have been derived from established impact test standards. Glassfiber-reinforced specimens are subjected to an instrumented impact test at constant impact energy. This is numerically investigated by a stacked-layer model, which used cohesive zone modeling to enable the simulation of matrix cracking, fiber fracture and delamination. The resulting projected damage areas, as well as the force and deflection histories, were evaluated and section cuts were examined to discuss the damage morphology, formation and propagation process. Significant effects on maximum deflection, compliance and dynamic behavior on the size and morphology of damage were found.
A solution methodology is introduced for the efficient computation of the acoustic field over restricted domains and for a frequency window. Typically, such partial field solutions include, for example, surfaces enclosing the radiating structure or even single points in the computational domain. The multiple-frequency partial-field (MFPF) method starts out by reformulating the finite element matrix system into a suitable shifted form. The DtN map is used as a radiation boundary condition and is interpreted as a low rank update of the matrix problem. The shifted standard form is then approximated by a rational matrix-valued Padé approximant and solved simultaneously over a frequency range. To obtain the Padé approximation, a banded unsymmetric Lanczos process is applied on the standard shifted form exploiting the matrix Padé-via-Lanczos connection. Numerical examples show the feasibility of the outlined procedure.
This paper addresses the efficient solution of acoustic problems in which the primary interest is obtaining the solution only on restricted portions of the domain but over a wide range of frequencies. The exterior acoustics boundary value problem is approximated using the finite element method in combination with the Dirichlet-to-Neumann (DtN) map. The restriction domain problem is formally posed in transfer function form based on the finite element solution. In order to obtain the solution over a range of frequencies, a matrix-valued Padé approximation of the transfer function is employed, using a two-sided block Lanczos algorithm. This approach provides a stable and efficient representation of the Padé approximation. In order to apply the algorithm, it is necessary to reformulate the transfer function due to the frequency dependency in the nonreflecting boundary condition. This is illustrated for the case of the DtN boundary condition, but there is no restriction on the approach which can also be applied to other radiation boundary conditions. Numerical tests confirm that the approach offers significant computational speed-up.
A Krylov subspace projection method which provides simultaneous solutions of the Helmholtz equation at multiple frequencies in one solution step is presented. The projector is obtained with an unsymmetric block Lanczos algorithm applied to a transfer function derived from a finite element discretization. This approach is equivalent to a matrix-valued Padé approximation of the transfer function. The proposed method is an extension of the formulation presented in [J. Comput. Acoust. 8 (2000) 223] to unsymmetric systems and allows the treatment of a much wider range of practical problems, including near-field and fluid–structure interaction computations
Flame sprayed Al-12Si coatings for the improvement of the adhesion of composite casting profiles
(2008)
In this study, flame sprayed Al-12Si coatings were produced on the surface of inlays (aluminum profiles) of composite castings parts. The aim was to enhance the strength between the joining partners inlay and cast. Due to the high surface roughness and the presence of pores in the coatings, combined with the formation of an intermetallic phase at the interface, the adhesion of flame sprayed inlays could be enhanced by a factor of 2 compared to blank inlays and by a factor of 1.3 when compared to sand-blasted inlays. However, results also show that gaps are present, mostly at the interface between the inlays and the flame sprayed coatings, and these gaps have a negative effect on the joining strength of the composite casting parts. Therefore, optimizing the adhesion of the coating on the Al profiles via an improvement in both the sand-blasting and the flame spraying parameters would be beneficial for further enhancement of the adhesion of composite casting parts.
Die vorliegende Arbeit befasst sich mit Untersuchungen zur thermischen Ermüdung der Magnesiumbasislegierung AZ31 im Temperaturbereich zwischen +50°C und +290°C. Die Experimente erfolgten unter konstanter Totaldeformation (out-of-phase-Beanspruchung) und es wurde der Verlauf der Spannungsamplitude sowie der plastischen Dehnungsamplitude über die Zahl der Temperaturzyklen ermittelt. Insbesondere wurde der Einfluss einer mechanischen Oberflächenbehandlung (Festwalzen) sowie von Haltezeiten auf den Verlauf der Schädigung untersucht. In beiden Fällen konnte kein signifikanter Unterschied zu unbehandelten Proben bzw. Beanspruchungen ohne Haltezeit festgestellt werden, welches auf die Wechselwirkungen zwischen Verformungs- und Rekristallisationsprozessen bei der thermischen Ermüdung zurückzuführen ist.
Obwohl das Laserdurchstrahlschweißen sehr reproduzierbar arbeitet, können Fehler aus den Vorprozessen Compoundieren, Spritzgießen etc. das Schweißergebnis negativ beeinflussen. Dem Anwender steht inzwischen eine breite Palette an Prozessüberwachungsmethoden zur Verfügung, um eine gleich bleibende Produktqualität zu erzielen.
In the context of the “InnMag” project, partners from industry and science are co-operating to investigate the issues involved in adapting established production processes to the material Mg. The project's aim is to further the deployment of Mg interior parts in civil aircraft. The project covers every production step, from alloy selection, Mg ingot melting, alloying, direct chill casting, extruding, machining, surface treatment and component assembly. This paper discusses the project's targets and the results arrived at so far, particularly in the areas of direct chill casting and extrusion.
A lot of dental alloys are available on the market. Among these alloys, there are the conventional alloys, the so called casting alloys used without ceramics, the bonding alloys used with high fusing ceramics and the universal alloys used without or with low fusing ceramics. It is im portant to know the physical and mechanical properties of these materials but also their biocompatibility and their resistance to corrosion. Dental alloys are generally placed in the mouth for many years, they must not induce adverse biological reactions such as gingival swelling and erythema, mucosal pain and lichenoid reactions. Although these troubles are often caused not by the materials itself (1, 2), they can be induced by the metallic ions released during their corrosion. In order to decrease the risks to the health, it is necessary to study the corrosion of the dental alloys. Currently, the ISO 10271 Standard (3), describes 3 different corrosion tests: a static immersion test (chemical corrosion), an electrochemic al test and a tarnish test. However, there are no indications yet about the possible interpretation of test results. In this paper, we propose a method to compare and classify the dental alloys in relation to their chemical and electrochemical corrosion results. METHODS: The material tested are pure metals such as gold, palladium, silver, copper and zinc as well as dental alloys which are commercially sold (see Table 1). 54 different materials have been tested. A minimum of four samples of each material were tested by electrochemic al corrosio n and a minimum of three in chemical test. The samples were cast and prepared as indicated by the manufacturer and by the ISO 10271. For the electrochemical test, the samples are in the form of disks 11 mm in diameter. They are tested with a potentiostat/galvanostat Voltalab Model 21. For the chemical test, the samples are rectangular with the dimensions 35X10X1.7 mm. The solution used and the operating conditions are described in the ISO 10271. The concentration of metallic ions released is measured by Induced Coupled Plasma
Das Kommissionieren zählt zu den arbeitsintensivsten Aufgaben in der Logistik. Aus diesem Grund ist es wichtig, möglichst genau die erwarteten Prozesszeiten für diese Aufgabe zu bestimmen. Ein verbreiteter Ansatz für die Bestimmung von Prozesszeiten für manuelle Tätigkeiten beim Kommissionieren ist die Methods-Time-Measurement (MTM). Um eine Vorgabezeit mittels MTM zu bestimmen, müssen Einflussfaktoren spezifiziert werden. Dieser Beitrag zeigt anhand der Greifzeit auf, wie diese Einfluss-faktoren auf Grundlage von Artikelstammdaten bestimmt werden können. Weiterhin wird der Unterschied zwischen einer für jeden Artikel individuell bestimmten Greifzeit und der Greifzeit basierend auf repräsentativen Eigenschaften von Artikelgruppen verglichen. Wesentlich wird dabei die mittels MTM bestimmte Greifzeit durch das Gewicht und die Abmessungen (Sperrigkeit) beeinflusst.
In-plant milk-run systems represent transportation systems, where materials are delivered from a central storage area to several points of use on fixed routes and in short and defined intervals. Milk-run systems generally enable frequent deliveries in low lot sizes with short lead times and low inventories at the points of use. Thus, stable and reliable system operation is crucial to avoid delays and material shortages. In industrial practice, milk-run trains usually share resources, for example, loading areas and technology and use the same tracks, leading to dependencies between routes and possible traffic jams and blockages, which significantly affect cycle times and may lead to instabilities in the system. We present a simulation model to analyse in-plant milk-run systems with a focus on typical traffic situations. We describe its application to a large industrial case study in detail and derive recommendations for designing routes with low risk of delays.
In-plant milk-run systems are transportation systems, where materials are delivered from a central storage area to several points of use on defined routes and in short intervals. Milk-run systems generally enable frequent deliveries in smaller lot sizes with short lead times and low inventory at the points of use. In real milk-run systems, the number of deliveries per interval varies due to, e.g., variations in the production program. To enable efficient and stable milk-run system operations, these systems therefore must be able to cope with peaks in the number of deliveries. We develop different strategies for handling these delivery peaks and evaluate them with respect to delivery cost, lead time and service level using real material consumption data from two large companies from the automotive industry.
Manuelle Kommissioniersysteme sind aufgrund ihrer Flexibilität weit verbreitet, jedoch treten bei diesen auch vermehrt Kommissionierfehler auf, die weitreichende Folgen haben können. Deshalb werden zu Beginn des Beitrags die Auswirkungen und Ursachen von Kommissionierfehlern betrachtet. Der Fokus des Beitrags liegt auf der Darlegung von Möglichkeiten zur Fehlervermeidung. Dabei wird ein ganzheitlicher Ansatz verfolgt, der Maßnahmen aus den Handlungsfeldern Technik, Prozess, Organisation und Motivation umfasst. Als Ausblick auf zukünftige technische Hilfsmittel zur Fehlervermeidung wird das Augmented-Reality-unterstützte System Pick-by-Vision aus der Forschung vorgestellt, das wesentliche Vorteile existierender Techniken der Informationsbereitstellung vereinigt.
First results regarding the realisation of multi-material components manufactured by Laser Beam Melting of polymers and metals are published. For realising composite structures from polymer powders by additive manufacturing, at first relevant material properties regarding compatibility have to be analysed. The paper shows the main requirements for compatibility between different materials and offers first results in form of a compatibility matrix of possible combinations for composite structures.For achieving gradient properties of additively manufactured metal parts by using composite materials the composition of alloying components in the powder and adapted process strategies are varied. As an alternative to atomizing pre-alloyed materials, mixtures of different powders are investigated.
For human machine interaction a control ar chitecture for the force controlled guidance mode of a five axis robot is developed. This enables a human operator to move the robot easily by applying forces at th e end-effector. The position and th e path can then be tracked and stored for a later reuse. The control archit ecture is also used in a hybrid mode where it is possible to control chosen workspace coordinates with a path controller and others with a force controller. The hybrid mode is especially used to cut tissue material with a scalpel which is mounted at the robots effector.
By simultaneous laser beam melting (SLBM), parts consisting of different polymer powders can be additively manufactured within one building process. Besides the advantages of conventional LBM, e.g., not needing additional tools and being able to realize parts with almost any geometry, different product requirements can be achieved within a single part. Product requirements may be different chemical resistances or haptic material properties. Therefore, SLBM enlarges the application field for additive manufacturing in general. In the process, two different materials are deposited on the building platform and preheated a few degrees below the melting temperature of the lower melting polymer by infrared emitters. Afterward, a CO2 laser (λ = 10.6 μm) provides the energy for the temperature difference between the preheating temperatures of both materials. Finally, a digital light processing chip is used to achieve simultaneous and flexible energy deposition for melting both preheated polymers. By illuminating the chip with a laser, parts of the beam can be flexibly guided onto the powder bed or into a beam trap. As laser, a single mode thulium laser (λ = 1.94 μm) is used. After melting the layer, a new layer is deposited and the process starts anew. In this paper, polypropylene and polyamide 12 are used as materials. After analyzing the material and melting behavior during the process by a high-resolution thermal imaging system, the parts are qualified regarding their material compatibility at the boundary zone and porosity by cross sections.
The generation of multi-material components by laser beam melting (LBM) is a challenge which requires the invention of new coating devices for preparation of arbitrary powder patterns. One solution is the usage of vibration-controlled nozzles for selective deposition of polymer powders. Powder flow can be initiated by vibration enabling a start-stop function without using any mechanical shutter. In this report, the delivery of polymer powder by vibrating nozzles is investigated with respect to their application in LBM machines. Therefore, a steel nozzle attached to a piezo actor and a weighing cell is used in order to measure the stability and time-dependence of the powder mass flow upon vibration excitation with the usage of different kind of powder formulations. The results show that precompression of the powder inside the nozzle by vibration excitation is essential to realize a reliable start-stop function with reproducible discharge cyles and to prevent a initial flush of powder flow. Moreover, the use of different powder materials showed that mass flow is even possible with powders which are not optimized regarding flowability, but is readily enhanced with a factor of 2 to 3 by admixing Aerosil® fumed silica.
Abstract — In this report, the dry delivery of polyamide 12 (PA 12) powder for the preparation of powder layers in laser beam melting (LBM) is investigated. Therefore, an experimental setup was built which consists of a glass nozzle assembled on a piezo-electric actuator. By applying a sinusoidal voltage signal to the actuator, the nozzle is set into vibration mode which enhances the powder delivery through the nozzle. By using this effect, powder mass flow is controlled and a valve-like start and stop function is realized. In order to identify suitable process parameters, a broad range of vibration modes were investigated using two nozzles made from glass with different orifice diameters. Therefore, the vibration frequency and the voltage signal of the actuator were varied and the resulting mass flow was detected by a balance. It was found that both the frequency and the voltage signal affect the mass flow and its stability but with different impact. Moreover, powder lines were deposited with different velocities in order to characterize the setup regarding applicability for highly selective powder deposition for LBM.
By selective laser sintering (SLS), polymer powders are molten layer by layer to build conventional prototypes or parts in small series with geometrical freedom that cannot be achieved by other manufacturing technologies. The SLS process is mainly defined by the beam–matter interaction between powder material, laser radiation and different material characteristics by itself. However the determination of these different material characteristics is problematic because powder material imposes certain requirements that cannot sufficiently be provided by conventional measurement methods. Hence new fundamental investigation methods to determine the optical and thermal material characteristics like the thermal diffusivity, thermal conductivity, or the influence of different heating rates on the melting behavior are presented in this paper. The different analysis methods altogether improve the process of understanding to allow recommendations for the future process controlling.
Selective Laser Sintering (SLS) is an additive manufacturing technique whereby a laser melts polymer powder layer by layer to generate three-dimensional parts. It enables the fabrication of parts with high degrees of complexity, nearly no geometrical restrictions, and without the necessity of a tool or a mold. Due to the orientation in the building space, the processing parameters, and the powder properties, the resulting parts possess an increased surface roughness. In comparison to other manufacturing techniques, e.g. injection molding, the surface roughness of SLS parts results from partially melted powder particles on the surface layer. The actual surface roughness must thus be characterized with respect to the part's eventual application. At the moment, there is no knowledge regarding which measuring technique is most suitable for detecting and quantifying SLS parts' surface roughness. The scope of this paper is to compare tactile profile measurement methods, as established in industry, to optical measurement techniques such as Focus Variation, Fringe Projection Technique (FPT), and Confocal Laser Scanning Microscope (CLSM). The advantages and disadvantages of each method are presented and, additionally, the effect of tactile measurement on a part's surface is investigated.
Powder based Additive Manufacturing technologies offer huge potential for building parts with almost no geometrical restrictions, but both the process controlling as well as the part properties are strongly dependent on different material characteristics of the material, like the flowability. In this work, different weight percentages of nano-scaled silica dioxide particles (Aerosil®) are admixed to pure polyethylene and polypropylene powder and the resulting flowability is determined. Besides using the Hausner ratio as standardized value, the degree of coverage is introduced as a new characteristic to quantify the powder flowability. The degrees of coverage are compared to the Hausner ratios to allow a discussion and evaluation about the different characteristic values. Additionally, tensile bars consisting of polypropylene are generated to determine the porosity by cross sections and the mechanical part properties by tensile testing. As mechanical part properties, the tensile strength and elongation at break are determined and the effects of different powder flowability on these properties are analyzed.
Bisher wurden TPM und Lean Production meist differenziert voneinander betrachtet. Der TPM-Gedanke ist jedoch die konsequente Fortführung des Lean Thinking. Ein effektives Anlagenmanagement ist die Voraussetzung für das Erzeugen eines Produktionsflusses. In der Vergangenheit wurde TPM häufig ohne die Basis eines Produktionssystems eingeführt. Der zweite Schritt erfolgte vor dem ersten. Logistische Themen und die Optimierung von Arbeitsplätzen mitarbeiterintensiver Bereiche wurden ebenfalls nur mit geringer Tiefe behandelt. Die OEE (Overall Equipment Effectiveness) allein ist hierbei kein ausreichender Indikator für ein schlankes Produktionssystem, da eine Rüstzeitoptimierung mit der Reduzierung der Losgröße einen Zielkonflikt hervorrufen kann. Ein Ansatz, bei dem die EPEI-Kennzahl (Every Part Every Intervall) und die OEE gemeinsam betrachtet werden, stellt eine Lösung dar. Durch die verstärkte Fokussierung auf Ganzheitliche Produktionssysteme rückt TPM als ein wichtiger Baustein, oder bei einer entsprechenden Weiterentwicklung zum System, als aufbauender Ansatz in den Blickpunkt der Unternehmen.
In this paper, first results regarding the realization of multi-material parts by Simultaneous Laser Beam Melting (SLBM) of polymers are presented. This new approach allows the layerwise generation of parts consisting of different polymer materials within one building process. Besides the typical advantages of additive manufacturing technologies, such parts can fulfill different product requirements concomitant and therefore could enlarge the overall field of application. The powder materials used for this paper are polyethylene (PE) and a polyamide based thermoplastic elastomer (TPE). After depositing the powder materials next to each other, infrared-emitters heat the lower melting polymer and a CO2 laser provides the preheating temperature of the higher melting polymer. In the last step, a thulium fibre laser melts the two preheated powders simultaneously. The realized specimens are characterized by cross sections and their tensile strengths are determined. Additionally, the new approach of the simultaneous energy irradiation is investigated using a Finite Element Analysis in order to gain a more profound process understanding. In that sense, the influence of the size of the exposure area on the reachable maximum temperatures inside that area was analyzed by the simulation and compared to experimental studies.
In this paper, first results regarding the realization of multi-material parts by Simultaneous Laser Beam Melting (SLBM) of polymers are presented. This new approach allows the layerwise generation of parts consisting of different polymer materials within one building process. Besides the typical advantages of additive manufacturing technologies, such parts can fulfill different product requirements concomitant and therefore could enlarge the overall field of application. The powder materials used for this paper are polyethylene (PE) and a polyamide based thermoplastic elastomer (TPE). After depositing the powder materials next to each other, infrared-emitters heat the lower melting polymer and a CO2 laser provides the preheating temperature of the higher melting polymer. In the last step, a thulium fibre laser melts the two preheated powders simultaneously.The realized specimens are characterized by cross sections and their tensile strengths are determined. Additionally, the new approach of the simultaneous energy irradiation is investigated using a Finite Element Analysis in order to gain a more profound process understanding. In that sense, the influence of the size of the
exposure area on the reachable maximum temperatures inside that area was analyzed by the simulation and compared to experimental studies.
Purpose – The purpose of this paper is to demonstrate the processability of cohesive PE-HD particles in laser beam melting processes (LBM) of polymers. Furthermore, we present a characterization method for polymer particles, which can predict the quality of the powder deposition via LBM processes. Design/methodology/approach – This study focuses on the application of dry particle coating processes to increase flowability and bulk density of PE-HD particles. Both has been measured and afterwards validated via powder deposition of PE-HD particles in a LBM machine. Findings – For efficient coating in a dry particle coating process, the PE-HD particles and the attached nanoparticles need to show similar surface chemistry, i.e. both need to behave either hydrophobic or hydrophilic. It is demonstrated that dry particle coating is appropriate to enhance flowability and bulk density of PE-HD particles and hence considerably improves LBM processes and the resulting product quality. Originality/value – At present, in LBM processes mainly polyamide (PA), 12 particles are used, which are so far quite expensive in comparison to, for example, PE-HD particles. This work provides a unique and versatile method for nanoparticulate surface modification which may be applied to a wide variety of materials. After the coating, the particles are applicable for the LBM process. Our results provide a correlation between flowability and bulk density and the resulting product quality.
This study increases the basic understanding of optical material properties of polymer powders used in selective laser sintering (SLS). Therefore, different polymer powder materials were analyzed regarding their optical material properties with an integration spheres measurement setup. By the measurements a direct connection between the absorption behavior of the solid material and the overall optical material characteristics of the same material in powdery form could be shown. The results were used to develop an advanced explanation model for the optical material properties of powders. At present, existing explanation models only consider the occurring of multiple reflections in the gaps between the particles to explain the overall optical material properties of powder materials. Thus, by also considering the absorption behavior of the single particles, the basic understanding of the beam-matter interaction and their effect on the optical material properties of powder materials can be expanded.
Cardboard Engineering 2.0
(2014)
Das Material Karton ist in heutigen Fertigungen für die schnelle Umsetzung von Ideen aus einem Kaizen-Prozess ein gängiger Werkstoff. Die Vorgehensweise wird auch als Cardboard Engineering bezeichnet. Aber die Entwicklung geht weiter. Die immer weiter verbreiteten 3D-Drucktechnologien ermöglichen die schnelle Generierung von Vorrichtungen, die deutlich höhere Anforderungen hinsichtlich Präzision, Robustheit und Komplexität erfüllen.
In diesem Beitrag wird eine Theorie zur taktorientierten Fertigungssteuerung entwickelt. Es wird der kleinste Repräsentant einer taktorientiert gesteuerten Werkstatt ermittelt - das Ein-Ressourcen- Modell. Durch die Modifikation des Trichtermodells kann ein allgemeingültiges Beschreibungsmodell des Produktionsprozesses bei taktorientierter Fertigungssteuerung erarbeitet werden - das taktorientierte Trichtermodell. Es ermöglicht die Darstellung der Arbeitsbestände im aktuellen Bearbeitungstakt und der des nachfolgenden Taktes. Weiter wird das taktbasierte Trichtermodell in ein taktbasiertes Durchlaufdiagramm überführt. Hiermit kann das Bestandsverhalten des Ein-Ressourcen-Modells über der Zeit dargestellt werden. Das optimale Bestandsverhalten pro Takt kann durch ein idealisiertes Durchlaufdiagramm beschrieben werden. Bei realer Auslastung der Ressource entstehen schwankende Arbeitsbestände pro Takt. Hierbei werden durch zu geringe Bestände pro Takt Auslastungsverluste an der Ressource erzeugt. Durch zu hohe Bestände pro Takt entstehen ohne Kapazitätsanpassungen Verspätungen.
Machine allocation planning in job-shop production is challenging due to the high variability of machining times. The tact-time based production control reduces planning effort also the flow of orders in the shop floor is more predictable. This article takes a deeper look at a single production unit controlled tact based. By enhancing the funnel model and looking at the stock behaviour of production units, a deeper understanding of tact-time based production control is gained.
Die Regensburg Robotics Research Unit entwickelt Regelungsarchitekturen für Telerobotiksysteme für den industriellen Einsatz. Der Beitrag beschreibt das lokale und globale Regelungsmodell hinsichtlich Stabilität und Transparenz auf der Basis der von Lawrence und Yokokohji vorgestellten Regelungsarchitektur und zeigt Simulationsergebnisse auf. Die Modellbildung des geregelten Manipulators, die Kopplung des Operators und des Teleoperators und sowie die Übertragungsfunktion werden dargestellt. Die Simulation des vorgestellten Algorithmus in Matlab/Simulink wird durchgeführt. Innerhalb der Simulationsumgebung ist als Regelstrecke unter der Annahme einer idealen, lokalen Regelung eine im Raum bewegliche Punktmasse modelliert. Die vorgestellte Regelungsarchitektur liefert innerhalb der durchgeführten Simulation vor allem im niederfrequenten Bereich sehr gute Ergebnisse. Die nächsten Schritte sind die experimentelle Evaluierung der lokalen Architektur und der globalen Vierkanalarchitektur an den Robotern.
Der Beitrag beschreibt den Systemaufbau für die Risikobeurteilung zur Realisierung einer sicheren Mensch-Maschine-Kollaboration und stellt die vorgeschriebene Risikobeurteilung gemäß DIN EN ISO 10218-1:2012-01 in folgende Schritten vor: Beurteilung der Erfahrenswerte und des Nutzerverhaltens, Festlegung der Grenzen des Roboters, Identifikation der Gefährdungen und Risikoeinschätzung in den dimensionen Ausmaß, Exposition, Eintrittswahrscheinlichkeit und Vermeidungsmöglichkeit. Die Umsetzung in eine Steuerung, die Steuerungsarchitektur und die eingesetzten Komponenten zur Realisierung einer sicheren Abstandsüberwachung werden beschrieben und in Blockschaltbildern grafisch dargestellt. Die Validität der Sicherheitsfunktion wird diskutiert.
Die 3D-Daten, die bei der Fertigungsplanung in CAD/CAM-Systemen vorliegen, bilden häufig auch die Spannsituation des Werkstücks ab. Mit einer vom LFW der OTH Regensburg entwickelten Software lassen sich die Konturen direkt auf den Rüstplatz projizieren. Im Rahmen des durch das Bayerische Staatsministerium für Bildung und Kultus, Wissenschaft und Kunst geförderte F&E-Projekt "AutoRüst" entwickelt das LFW Bausteine zum automatisierten Generieren von Rüstinformationen. Im Wesentlichen geht es dabei um zwei Schwerpunkte: erstens das datenbankgestützte Verwalten von Spannsituationen inklusive der Unterstützung und Überprüfung beim Aufbau sowie zweitens die bedarfsgerechte Visualisierung des Programmablaufs für die Einfahrprozedur an der Werkzeugmaschine. Bei beiden Themenkomplexen werden bereits vorhandene Daten (3D-Spannsituation, NC-Programm mit Maschinenraumsimulation) genutzt, um konfigurierbare Rüstdokumente zum Spannen und Einfahren zu erzeugen. Im Idealfall muss der NC-Programmierer also nur wenige bis gar keine zusätzlichen Eingaben tätigen. Neben der reinen Zeitersparnis wird so auch eine deutlich gesteigerte Prozesssicherheit beim Übertragen der virtuellen Welt in die reale Fertigungswelt erreicht. Das vom LFW entwickelte Modul zur Visualisierung der Spannsituation kann flexibel in den Fertigungsbetrieben integriert werden. Gerüstet werden kann sowohl in der Maschine, auf einer zweiten Palette als auch auf einem externen Rüstplatz. Einzige Randbedingung ist, dass der Laserprojektor auf den Tisch projizieren kann, idealerweise senkrecht von oben. Die Software analysiert in einem ersten Schritt die vorhandene 3D-Baugruppe und erzeugt anhand der Lage der Bauteile eine Montagereihenfolge, die natürlich angepasst werden kann. Ebenso können Einzelteile gruppiert werden, sodass diese bei der späteren Projektion auch als Gruppe projiziert werden. Unwichtige Baugruppenteile wie beispielsweise die Stützen der Spannpratzen oder die Muttern mit den Unterlegscheiben können vom weiteren Prozess ausgeschlossen werden. Auf der so geschaffenen Grundlage erzeugt die Software Projektionslinien auf dem zu positionierenden Bauteil mit einem einstellbaren Abstand (hier: 1 mm) zur Bauteilkante. Als Ergebnis wird eine Ausgabedatei im dxf-Format erstellt, die vom Laserprojektor verarbeitet werden kann. Die in der dxf-Datei auf Layern gruppierten Projektionslinien können dann ferngesteuert in der zuvor definierten Reihenfolge durchgeklickt werden, um die Spannelemente zu positionieren. Die Vorteile des Visualisierungsmoduls im Überblick: (1) Senken der Rüstzeit; (2) Erhöhen der Prozesssicherheit beim Rüsten (Positioniergenauigkeit der Spannelemente < 1 mm) und damit Kollisionsvermeidung; (3) Nutzen bereits vorhandener 3D-Informationen entlang der Prozesskette CAD/CAM-Fertigung; (4) Konturerzeugung direkt im CAM-System OPUS oder über unabhängige Software.
Die Anwendung von Kaizen ist in vielen Firmen ein selbstverständliches Element geworden. Dennoch variiert die Ausprägung eines kontinuierlichen Verbesserungsprozesses stark von Unternehmen zu Unternehmen. Ein wesentliches Hindernis, gutes Kaizen umzusetzen, ist der Mangel an Realisierungsmöglichkeiten. In Zeiten von Industrie 4.0 bestehen inzwischen zahlreiche Möglichkeiten, Ideen schnell und kostengünstig für eine Produktion zu generieren und damit nachhaltig die Produktivität zu steigern. Zentrales Element von Kaizen ist das zielgerichtete Experimentieren. Es werden Hypothesen aufgestellt und diese werden durch Experimente überprüft, so dass man aus den Ergebnissen lernen kann. Entscheidend ist die Fähigkeit, tatsächlich Experimente in einer Produktion ausführen zu können. Das heißt, Produktionsanlagen müssen mit unterschiedlicher Intensität verändert werden können. In erfolgreichen Unternehmen ist ein Betriebsmittelbau in der Lage, diese Experimente zügig durchzuführen. Häufig sind aber auch hier die Möglichkeiten einer schnellen Gestaltung eingeschränkt. Jede Form von Verbesserung führt zu optimierten Prozessen und einer besseren "Business Excellence". Innovationen, die zum Beispiel durch den Produktionsanlagenhersteller eingebracht werden, führen häufig zu einer sprunghaften Verbesserung. Diese Verbesserungen sind in jedem Fall wichtig, aber auch häufig für den Wettbewerb verfügbar, wenn das Wissen nicht bei einem hauseigenen Anlagenhersteller entsteht. Wenn zudem kleine Verbesserungen zu den Innovationen hinzukommen, können die Prozesse zusätzlich optimiert werden. Sind die Verbesserungen eher kurz- als langzyklisch liegt es auf der Hand, dass ein schnelles Erreichen des Verbesserungsniveaus erfolgt. Neben dem Zeitgewinn ist eine kurzzyklische Vorgehensweise deutlich inspirierender und erschließt das volle kreative Potenzial des Verbesserungsteams.
Kaizen is state of the art for high efficient optimization used by many companies. Nevertheless the variations of this method differ from company to company. A big obstacle to realize good kaizen is due to the lack of possibilities to generate different devices. In times of smart factories and increasing digitalization plenty of possibilities can be used to make ideas happen. This is the opportunity to optimize manufacturing systems in a short cyclic and fast way.
A management system for dynamic and interorganizational design processes in chemical engineering
(2004)
Design processes in chemical engineering are hard to manage. The design process is highly creative, many design alternatives are explored, and both unexpected and planned feedback occurs frequently. Thus, it is inherently difficult to manage the workflow in design processes, i.e., to coordinate the effort of experts working on tasks such as creation of flow diagrams, steady-state and dynamic simulations, etc. Conventional project and workflow management systems support the management of design processes only to a limited extent. In contrast, the management system AHEAD is designed specifically for dynamic design processes. In addition, AHEAD supports the management of interorganizational design processes. A subprocess may be delegated to a contractor, which receives information only about those parts of the overall process that are relevant for the contract. The management systems of the client and the contractor are coupled at run time such that both systems maintain up-to-date state information. The contract may be changed at any time according to the rules of a pre-defined change protocol. To validate this approach to the management of dynamic and interorganizational design processes, the AHEAD system has been applied to a comprehensive case study, namely the conceptual design and basic engineering of a chemical plant for producing polyamide 6.
Data-driven models are developed to predict the mechanical properties of polycrystalline materials. The case study is the prediction of the yield strength of a 3D-printed 316L steel from morphological and crystallographic features. Three different artificial intelligence models including feed-forward (FNN), convolution (CNN), and graph (GNN) neural networks are employed to train the data-driven models and are compared in terms of performance and computational requirements. The dataset required for training is generated by performing crystal plasticity finite element simulations. The FNN model has the smallest input size and takes in some statistical parameters describing the material microstructure, but its accuracy is relatively low. The CNN approach inputs voxel-based realizations of the microstructure and is able to give accurate estimations; however, its training process is time-consuming and computationally expensive. In the GNN approach, the polycrystalline material is represented by a graph whose nodes and lines represent the grains and adjacency between grains. It is observed that GNN yields a better performance compared to the other two approaches and has the capability of handling complex tasks.
Ablaufoptimierung in einer Halbleiterfertigung (Scheduling Optimization in Semiconductor Industry
(2022)
A rule-based, iterative approach is often used for the scheduling of automated plants. In this study, a wet bench from the semiconductor industry is used to show the potential that is lost as a result and how the scheduling can be optimized. Furthermore, it is investigated how adjustments to the plant design can further reduce the average cycle time.
Manually defined control limits remain a common strategy for quality control in manufacturing due to their ease of deployment on the shop floor compared to more advanced data analysis approaches. Despite their continued importance, there is no systematic method of defining these control limits. However, sub-optimal control limits can lead to undetected faults or cause unnecessary interruption to production. This manuscript presents an algorithm that systematizes this manual process into an efficient search task. We conceptualized the search task as a sequence of sub-problems that are based on the conventional steps taken by process experts when defining control limits. This algorithm can be integrated into an expert tool for shop floor personnel to automate the definition of control limits in annotated time series data. We demonstrate the efficacy of the control limits found by our algorithm by comparing them to those manually defined by process experts in real-world process data from the automotive industry. Furthermore, we show that our algorithm generalizes to traditional time series classification problems and achieves state-of-the-art performance on selected benchmark datasets. Our work is the first effort in automating the otherwise manual definition of control limits for fault detection.
Hot pressing of pure Ti and cast iron under vacuum formed a ~15 μm wide TiC-layer through the thermoreactive diffusion process. Nanoindentation testing of the TiC-layer revealed average hardness and elastic
modulus values of ~35 GPa and ~400 GPa, respectively. High-resolution indentation mapping indicated hardness change across the boundary with peak values observed within the TiC-layer. Solid state high temperature diffusion holds significant potential for developing uniform hard coatings on pure Ti/Ti-alloys.
In this report, the dry delivery of polyamide 12 powders by vibrating capillary steel nozzles is investigated and discussed regarding its potential for powder layer preparation in Laser Beam Melting. Therefore, a setup including a steel nozzle assembled on a piezoelectric actuator is presented, which enables the precise control over very small powder quantities by vibration excitation. An analysis reveals that the mass flow through the nozzle can be adjusted by the vibration modes in a certain range depending on the nozzle's specifications, whereas the vibration modes themselves show a complicated behaviour. Using a positioning system in combination with the vibrating nozzle, single-layer patterns consisting of polyamide 12 are produced and characterized regarding surface homogeneity and selectivity using a laser stripe sensor.
In recent years, the Tuned Mass Damper with inerter (TMDI) has received significant attention. The inerter is defined to exert a force that is in proportion to the relative acceleration of the two inerter terminals. Here, two TMDI topologies are investigated. The conventional topology is given by the inerter being in parallel to the spring and viscous damper of the TMDI. The other topology is the serial arrangement of spring, inerter and viscous damper being in parallel to the stiffness of the mass spring oscillator of the TMDI. While the first topology intends to increase the inertial force of the TMDI, the second topology aims at producing an additional degree of freedom. The considered TMDI concepts are simulated for harmonic and random excitations, with parameters set according to those described in the literature and with numerically optimized parameters which minimize the primary structure displacement response. The classical TMD is used as a benchmark. The findings are twofold. The conventional TMDI with typical inertance ratio of 1% and the very small value of 0.02% performs significantly worse than the classical TMD with the same mass ratio. In contrast, the TMDI with an additional degree of freedom can improve the mitigation of the primary structure if the inertance ratio is set very small and if the TMDI parameters are numerically optimized.
In tension-tension tests the amplitude stress as well as the mean stress can be adjusted to any desired level. For a common evaluation of all tension-tension tests amplitude and mean stresses should be substituted by an equivalent amplitude stress. For determination of these e quivalent stress the so called mean stress influence hast to be known. In the following, suitable models will be presented which allow a common evaluation of all tension-tension tests and also a general description of rope wire fatigue behavior.
Mobilkrane arbeiten regelmäßig in Regionen, in denen Temperaturen bis -60 °C herrschen. In sicherheitstechnisch bedeutsamen Anwendungen wird der Kranbetrieb eingestellt, und zwar nur, weil in den entsprechenden Regelwerken die niedrigste genannte Arbeitstemperatur -40 °C ist. Aber ist dies technisch zwingend? Es wird über Versuche mit Seilen und Seildrähten berichtet, die sowohl bis -95 °C als auch bei Raumtemperatur durchgeführt wurden. Sowohl das Ermüdungsverhalten der Seildrähte als auch die Bruchkraft der Seile sind bei Temperaturen von -60 °C besser als bei Raumtemperatur. Dagegen wird das Ermüdungsverhalten der Seile schlechter. Dies ist aber hauptsächlich verursacht durch das Verhalten des verwendeten Konservierungsstoffs. Im Betrieb sind die Seile zusätzlich mit Endverbindungen versehen. Diese Komponenten müssen ebenfalls solchen tiefen Temperaturen widerstehen. Untersuchungen, ob Seilendverbindungen bei Tieftemperatur geeignet sind, waren allerdings nicht Gegenstand dieses Berichts. Daher ist es ratsam, beim Betrieb bei Tieftemperatur die Intervalle der Seilinspektion zu verkürzen. Konservierungsstoffe können ihre Wirkung verlieren und zu beschleunigter Seilermüdung führen - zum Beispiel bei Auslegerverstellseilen von Mobilkranen - und das Zusammenwirken von Seilen und ihren Endverbindungen bei tiefen Temperaturen ist nicht ausreichend erforscht und dokumentiert. Insgesamt können Seile bei Temperaturen von -60 °C sicher betrieben werden, wenn sowohl die Seile als auch ihre Endverbindungen regelmäßig inspiziert werden.
In Mensch-Roboter-Arbeitszellen werden Teile eines Produktionsablaufs von einemv Menschen, andere von einem kollaborativen Roboter und wieder andere kooperativvin einem gemeinsamen Arbeitsbereich durchgeführt. Bisher werden das Potenzialvund der Mehrwert dieser Systeme noch nicht ausgeschöpft, weshalb ein systematischer Ansatz zur Definition der Arbeitsabläufe unerlässlich ist. Der Beitrag präsentiert einen iterativen, menschzentrierten Entwicklungszyklus für interaktive Mensch-Roboter-Anwendungen. Dieser Zyklus ergänzt die bisher verwendeten Ansätze der Automatisierung. Er beinhaltet Methoden der virtuellen Realität, um die Arbeitsabläufe iterativ evaluieren und dadurch den Entwicklungsprozess effizient gestalten zu können.
Due to the growing number of applications for Additive Manufacturing (AM), an increasing need for enhanced quality control methods exists. Here optical measurement techniques are often used for in-situ monitoring in AM. There is a great potential to standardize and improve applications of optical measurement devices in accordance to the increasing requirements of measuring tasks. Beside the optical material qualifications, especially process-oriented changes in optical effects are of great relevance for in-situ evaluations. The optical modifications may be attributed to aggregate specific phase transitions coming along with variable emitted wavelengths. A measuring setup with two integrations spheres and a heated process chamber have been developed to analyze the optical interactions of laser radiation and visual illumination with the powder. The process oriented analysis for selective laser sintering lead to improved operating conditions in the field of in-situ measurements in combination with an accurate evaluation of the absorption ratio of the examined powder.
The mechanical and microstructural investigation of polymer parts (polyamide 12) fabricated by Selective Laser Sintering as part of a Round Robin initiative is presented. The paper focuses on the microstructural analysis of the Round Robin samples and their evaluation regarding their effect on mechanical properties with respect to each other. Therefore optical microscopy on microtomed samples, X-ray computed tomography and Differential Scanning Calorimetry is used to determine the morphology of residual particle cores and of internal pores.
The mechanical properties of polymer parts built by Selective Laser Sintering are strongly related to the internal microstructure which differs with the applied production parameters. The paper focuses on the back tracing of the pore morphology of laser sintered polyamide-12 samples to the process parameters. Therefore, a data base is used which is supplied by a Round Robin initiative and includes mechanical tensile tests and the microstructural analysis of the pore morphology of several different sample charges built with different machines. The pore morphologies (porosity, pore density, pore shape and pore arrangement) measured by X-ray computed tomography are compared and discussed regarding the employed parameters and the resulting mechanical properties. The investigations point out that pore density is a superior indicator than porosity for mechanical issues. This is especially valid along the build direction since pore morphology has shown to be strongly anisotropic. Moreover, the analysis revealed that pore density is strongly affected by the process temperature, which is proved to be essential for the fabrication of mechanical robust parts using Selective Laser Sintering.
Conventional Selective Laser Sintering of polymers is restricted to the processing of single materials. The fabrication of components consisting of different material regions is a challenge which cannot be realized by standard coating devices basing on blades or rollers. Thus, advanced coating and deposition techniques are needed which enable the precise and reliable control over very small powder quantities in order to prepare arbitrary powder patterns with high accuracy and repeatability. In this report, the delivery of polymer powder by vibrating nozzles inside laser sintering machines is investigated. Therefore, a steel nozzle attached to a piezo actuator is integrated into a machine, whereas the nozzle itself features internal channels which allow the precise control over the powder temperature using heat transfer oil. The setup is used to study the influence of different system configurations on the powder deposition characteristics as resolution and layer surface roughness. The results show that temperature influences the mass flow depending on the material used and that a precise deposition of powder pattern with microscale resolution is possible with optimized parameters. Finally, the multimaterial powder pattern is fused by a new illumination strategy of laser sintering which is called Simultaneous Intensity-Selective Laser Sintering in order to demonstrate the potential of this new approach.
In order to understand the absorption characteristic, a ray trace model is developed by taking into account the reflection, absorption and refraction. The ray paths are resolved on a sub-powder grid. For validation, the simulation results are compared to analytic solutions of the irradiation of the laser beam onto a plain surface. In addition, the absorptance, reflectance and transmittance of PA12 powder layers measured by an integration sphere setup are compared with the numerical results of our model. It is shown that the effective penetration depth can be lower than the penetration depth in bulk material for polymer powders and, therefore, can increase the energy density at the powder bed surface. The implications for modeling of the selective laser sintering (SLS) process and the processability of fine powder distributions and high powder bed densities are discussed.
In this paper, the use of electrophotographic polymer powder transfer for the preparation of multi-material layers is discussed with respect to the application in powder bed-based additive manufacturing technologies as selective laser sintering (SLS). Therefore, the challenges of this task are considered verifying the critical process steps in order to develop a concept for an electrophotograhic laser sintering machine. On that basis, an experimental setup with a two-chamber design is realized which enables the investigation of the electrophotographic powder transfer at typical process conditions of SLS. Using this setup, transfer tests of polypropylene powder patterns were performed and qualitatively analyzed by photographic imaging. The results confirm the high potential of the application of electrophotography for multi-material powder deposition and show how a residual electrophotographic powder deposition can be achieved in general, which is independent from the already produced part height, in order to build up three-dimensional multi-material components.
Comparison between the optical properties of injection molded and additive manufactured components
(2018)
Fused Layer Manufacturing (FLM) is an additive technology based on polymer material extrusion. Due to variations in temperature during the manufacturing process and the resulting stress between the stacked layers, the final parts show anisotropic mechanical properties. One possible approach for their reduction is the immediate local preheating of the surface via laser radiation. At first, our research examines the influence of laser parameters as wavelength, power, velocity and area of impact for the preheating of the surface. In addition, an overview of possible parameter combinations is given based on the selection of raw materials, its colors, thicknesses and the manufacturing process. Initially, the absorption level of the materials regarding the emitted wavelength is detected using a spectrophotometer. Subsequently, preheating tests are conducted with different laser types while the temperature is determined by a thermal camera. The selected laser type is planned to get mounted on a prototype-machine for further in-situ preheating experiments on FLM parts during the manufacturing process.
Laser transmission welding is a well-known joining technology for welding thermoplastics. Although the process is already used industrially, fundamental process-structure-property relationships are not fully understood and are therefore the subject of current research. One aspect of these mentioned process-structure-property relationships is the interaction between the temperature field during the welding process, the weld seam morphology of semi-crystalline thermoplastics, and the weld seam strength. In this study, the influence of the line energy on the weld seam morphology of polypropylenes is analyzed. For this purpose, the size of spherulites in the weld seam is investigated, as well as different occurring phases of polypropylene (a- and b-phase). It is shown that both the spherulite size of the a-phase and the amount of b-phase increase with increasing line energy. For the explanation and discussion of the results, a temperature-dependent thermal simulation model is used to derive characteristic attributes of the temperature field (maximum temperatures, cooling rates, temperature gradients).
Laser transmission welding is a non-contact and efficient process technology for joining thermoplastic polymers. In the conventional process, laser sources in the wavelength range of 1 μm are usually used. Therefore, most of the laser radiation is transmitted through the upper joining partner and absorbed only in the lower joining partner. As a result, the possibilities to influence the temperature field especially in the upper joining partner are limited. To overcome these limitations, an additional thulium fiber-laser with a wavelength of 1.94 μm is used in this study and coaxially aligned with a diode laser. The use of an additional thulium fiber-laser leads to a significant absorption in the upper joining partner. Through this approach, it is shown that the temperature field and the weld seam geometry can be influenced by using these two different discrete laser wavelengths. Depending on the intensity distribution of both lasers, an increase of the size of the heat affected zone in the upper joining partner can be observed. In order to develop a better process understanding, a thermal finite element model is built up and verified by comparing the calculated size of the heat affected zone for different process parameters with the experimental data. The model is able to represent the influence of both laser sources on the temperature field and is used to calculate characteristics of the temperature field, such as maximum temperatures or cooling rates. The characteristics are then used to explain the weld seam morphology, such as occurrence and size of spherulitic structures in the weld seam.
A new approach to coat PA12 powders with laser-generated nanoparticles for selective laser sintering
(2018)
The modification of selective laser sintering (SLS) powder materials by nanoadditives offers the possibility to adapt the powder properties to the laser sintering process or the resulting part properties. To avoid agglomeration of the nanofiller, a new approach in which surfactant-free laser-generated colloidal nanoparticles are adsorbed onto the polymer surface directly in an aqueous solution is demonstrated. Based on this novel approach, polyamide 12 (PA12) powders are decorated with metal and oxide nanoparticles and processed via SLS. Electron microscopy and confocal laser scanning imaging are utilized to analyze the dispersion of the filler.
For structures made of carbon fiber-reinforced plastics (CFRP), fast, robust, and reliable repair technologies are mandatory for economical usage. In this paper, the authors explain their strategy and experiences. An automated process is proposed to achieve the challenging goals. A general overview on the origin, effects, and analysis of contaminants in CFRP structures and the relationship to the achievable strength of adhesive bonds are given. For the repair of composite structures using adhesive bonding, surface pretreatment is a key factor in terms of reliability and strength. Different surface treatment processes such as grinding, grit blasting, plasma and pulsed lasers treatments are discussed. Furthermore, the possibilities and technical implementation of an automated milling process for the repair of composite structures are presented. This change from manual production to automation tremendously improved the quality and duration of the repair and allows the creation of a uniform surface for adhesive bonding. Further integration of novel technologies is discussed and will further support and enhance the repair in the near future.
Ductile failure of structural metals is relevant to a wide range of engineering scenarios. Computational methods are employed to anticipate the critical conditions of failure, yet they sometimes provide inaccurate and misleading predictions. Challenge scenarios, such as the one presented in the current work, provide an opportunity to assess the blind, quantitative predictive ability of simulation methods against a previously unseen failure problem. Rather than evaluate the predictions of a single simulation approach, the Sandia Fracture Challenge relies on numerous volunteer teams with expertise in computational mechanics to apply a broad range of computational methods, numerical algorithms, and constitutive models to the challenge. This exercise is intended to evaluate the state of health of technologies available for failure prediction. In the first Sandia Fracture Challenge, a wide range of issues were raised in ductile failure modeling, including a lack of consistency in failure models, the importance of shear calibration data, and difficulties in quantifying the uncertainty of prediction [see Boyce et al. (Int J Fract 186:5-68, 2014) for details of these observations]. This second Sandia Fracture Challenge investigated the ductile rupture of a Ti-6Al-4V sheet under both quasi-static and modest-rate dynamic loading (failure in 0.1 s). Like the previous challenge, the sheet had an unusual arrangement of notches and holes that added geometric complexity and fostered a competition between tensile- and shear-dominated failure modes. The teams were asked to predict the fracture path and quantitative far-field failure metrics such as the peak force and displacement to cause crack initiation. Fourteen teams contributed blind predictions, and the experimental outcomes were quantified in three independent test labs. Additional shortcomings were revealed in this second challenge such as inconsistency in the application of appropriate boundary conditions, need for a thermomechanical treatment of the heat generation in the dynamic loading condition, and further difficulties in model calibration based on limited real-world engineering data. As with the prior challenge, this work not only documents the 'state-of-the-art' in computational failure prediction of ductile tearing scenarios, but also provides a detailed dataset for non-blind assessment of alternative methods.
Erstellung eines Grabwiderstandsmodells zur ganzheitlichen Simulation von Schaufelradantrieben
(2012)
The focus of this paper is the simulation of the thermal-mechanical fatigue behavior (TMF) of two single crystalline Nickel-based superalloys in a temperature range between 400 degrees C and 980 degrees C. The newly developed rhenium-free alloy Astra-3OptW and the rhenium-free alloy CMSX-6 are analyzed concerning the basic deformation mechanisms, i.e. elasticity, time-independent and time-dependent plasticity contributing to hardening. In detail, the relevant parameters for high temperature deformation are identified from isothermal creep experiments and used in a numerical model to simulate the deformation behavior under instationary thermal and mechanical loading. Special attention is focused on the determination of the hardening by the second phase (gamma'-precipitates) and their influence on time-dependent deformation and relaxation mechanisms. Therefore, the parameters describing the stress and temperature dependence of the creep rate (i.e. stress exponent n and activation energy Q) are interpreted in terms of a threshold stress taking into account the hardening contribution of the gamma'-phase. Thus, only a reduced effective stress is active for plastic deformation. Particular attention is focused on the accurate determination of the threshold stress as a function of temperature and applied stress from the Langeborg-Bergmann-plot. The comparison of the simulated TMF-deformation to the experimental TMF-data clearly indicates the accuracy of the model in predicting the resulting stresses induced by instationary thermal and mechanical loading. (C) 2016 Elsevier Ltd. All rights reserved.
Methanol, and more recently ethanol, have been deeply employed as adsorbate phase (refrigerant) in adsorption chiller and heat pump applications (e.g. refrigerator adsorption ice maker). The use of anhydrous alcohols however can cause several problems related to the corrosiveness of such molecules towards light alloys (from titanium to aluminium). The problem was already highlighted in bio-fuel technology where bio-ethanol was considered as a promise alternative to fossil hydrocarbons. Water content was observed as one of the main factors influencing corrosion rate. In the present works several accelerated corrosion tests on 6061 Aluminium alloy have been carried out in autoclave in a temperature range from 110 to 135 degrees C with different ethanol to aluminium mass ratio. Highly exothermic reactions related to aluminium oxidation, coupled to hydrogen evolution, have been recorded. The main drawback of hydrogen evolution is the formation of a stagnant layer over the heat exchangers surface, which can limit the ethanol vapour diffusion, thus reducing adsorption condensation rate. (C) 2016 Elsevier Ltd. All rights reserved.
Die Digitalisierung ist im produzierenden Gewerbe in vielen KMU immer noch schwach ausgeprägt. Viele Unternehmen verfügen nicht über die notwendigen Ressourcen, um das Thema Digitalisierung voranzutreiben. Es dominieren weiterhin die konventionellen Methoden zum Informationsaustausch in der Produktion. Mit dem Low-Cost-Digitalisierungsansatz soll genau für diese Unternehmen die Chance zum Einstieg in die Digitalisierung mit einfachen, aber dennoch effizienten Mitteln ermöglicht werden.
In modernen Produktionen ist Lean Manufacturing einer der wichtigsten Treiber für Produktivitätssteigerungen. Durch neue Entwicklungen im Bereich Industrie 4.0 können Impulse im Lean Manufacturing gegeben werden. An der OTH Regensburg wird getestet, wie kostengünstige Kamerasysteme helfen können, Verschwendungen sichtbar zu machen und zu minimieren. Es zeigt sich, dass auch mit geringen Investitionskosten neue Potentiale zur Verschwendungsreduktion aufgedeckt werden können.
Quality and reliability are of the utmost importance for manufacturing in the optical and medical industries. Absorber-free laser transmission welding enables the precise joining of identical polymers without additives or adhesives and is well-suited to meet the demands of the aforementioned industries. To attain sufficient absorption of laser energy without absorbent additives, thulium fiber lasers, which emit in the polymers’ intrinsic absorption spectrum, are used. Focusing the laser beam with a high numerical aperture provides significant intensity gradients inside the workpiece and enables selective fusing of the internal joining zone without affecting the surface of the device. Because seam size and position are crucial, the high-quality requirements demand internal weld seam monitoring. In this work, we propose a novel method to determine weld seam location and size using optical coherence tomography. Changes in optical material properties because of melting and re-solidification during welding allow for weld seam differentiation from the injection-molded base material. Automatic processing of the optical coherence tomography data enables the identification and measurement of the weld seam geometry. The results from our technique are consistent with microscopic images of microtome sections and demonstrate that weld seam localization in polyamide 6 is possible with an accuracy better than a tenth of a millimeter.
In human-robot assembly cells, some tasks in a production process are carried out by the user, others by the robot, and some tasks are carried out in collaboration. However, the potential and advantages of such systems have not yet been fully harnessed. A systematic approach is needed to design cooperative workflows. Here, an iterative, user-centred development cycle is presented for interactive human-robot applications, complementing traditional automation. Virtual reality development is applied to evaluate the workflows to be defined and to develop a more efficient overall design cycle.
Fluctuations of material properties are one reason for the occurrence of cracks and waviness in series production of car body parts. Especially fluctuating tribological conditions have an effect on the friction behavior and thus on the material flow. So far fluctuating material properties are not considered in the standard FE-simulation and consequently not in the tool design. In order to enhance the accuracy of the simulation result and thus improve the tool design regarding a robust process, the appearance of batch fluctuations has to be consistently understood. Therefore, the impact of varying lubricant quantities and roughness have been investigated. Several batches have been analyzed to identify the main influencing parameter regarding the friction behavior. Flat strip-drawing tests have been performed to determine the friction coefficient. The investigations have been performed by using material from the series production, as delivered. Since the amount of lubricant turns out to be the main influencing factor, the characteristics and appearance of the lubricant distribution has been analyzed in a further step. The analysis has shown that the distribution of the lubricant changes within one coil over the coil width and length. In addition, the time of storage has been identified as one main influencing factor on the homogeneity of the lubricant distribution over the coil width. Based on these findings, a method has been developed to map the series production conditions regarding the friction conditions in the simulation. Hence, simulations were performed using a side frame blank with different friction conditions, to investigate the impact on the forming result. The results reveal that by considering realistically existing tribological conditions, more scrap is to be expected compared to the conventional simulation. This leads to the conclusion that previous simulation results are too optimistic. Consequently, the introduced method offers the potential to optimize the tool design by considering fluctuating tribological conditions already in the process of development. Thus, it is possible to reduce scrap and increase productivity.
The focus of this paper is the simulation of fatigue crack growth of the coated single crystalline nickel-based superalloy PWA 1484 under thermal mechanical loading. Thus, two physical models are superimposed in terms to firstly calculate the deformation behavior under instationary thermal and mechanical loading (TMF) and secondly to model crack propagation after initial brittle cracking of the coating layer on the basis of cyclic crack tip opening displacement (CTOD). All material parameters implemented in the models were evaluated from monotonic isothermal tensile and creep tests as well as from isothermal low cycle fatigue (LCF) experiments. The calculated fatigue crack growth was validated by in situ crack growth measurements using the beachmark technique. Hence, crack propagation initiated by the brittle coating system closely to the experimental results using rectangular flat specimen geometry instead of corner-crack (CC) specimens. The comparison of the simulated lifetimes to the experimental results provides remarkable accuracy of the physically-based lifetime model.
The focus of this paper is the characterization of the influence of the temperature rates on the TMF lives. Therefore static and the dynamic calibrations of the temperature measurement devices were compared by a custom-built calibration specimen, which included five internal mantle thermocouples. Additionally the temperatures were measured on the specimens' surface. The experimental setups used were compared by executing TMF pre-test with the identical single-crystalline specimen. Subsequently TMF tests on coated single-crystalline Nickel-based superalloy PWA 1484 were carried out with temperature rates of 10K/s and 20 K/s. Finally the deviations of the determined TMF lives were evaluated.
The development of reconfigurable planar four-bar linkages by applying the tensegrity principle is considered. Conventional quadrilateral linkages enable two operation modes differing in the kinematic behavior. However, a change between these states is not possible due to the geometric constraints. To enable a reconfiguration between the different modes one-sided limited nonholonomic constraints are introduced in this work. This issue is realized by applying ropes that cannot resist compression. However, to guarantee an appropriate load case in operation a prestress within the mechanism is required. Hence, the linkage is extended to a tensegrity-based mechanism. The structural dynamics are derived using the LAGRANGE formalism and the structural behavior is evaluated using numerical simulations. Furthermore, a prototype of an exemplary tensegrity-based mechanism is manufactured and experiments regarding the mechanical properties, in particular the reconfiguration, are performed. The results suggest the potential benefit of applying the tensegrity principle within conventional planar four-bar linkages.
Abrasive wear limits the lifetime of many machine components. Most empirical models relate the abrasive wear resistance to material hardness. In reality, however, other material properties are also influencing as scratch abrasion damage follows from a highly complex stress trajectory upon scratching. Numerical (finite element) simulation of scratch abrasion requires the use of a material damage model, which translates this stress trajectory into material degradation and removal. Most damage models include the first two stress invariants. However, fully incorporating the complex stress trajectories that occur during scratch abrasion may require damage models with dependence of the third deviatoric parameter (Lode angle). This paper serves as an a-priori study to evaluate the stress states that may occur during scratch abrasion. Three mechanisms (ploughing, wedging, cutting) are considered. Hereto, the results of an extensive parametric study using elastic-plastic finite element simulations of a scratch indentation process are discussed. Complex, non-proportional variations in stress state values are observed to occur during scratch abrasion. Distinct stress state trajectories are identified for the three abovementioned mechanisms. These variations are critically discussed to motivate a selection of suitable damage models for rigorous finite element analysis of the wear processes associated with scratch abrasion.
The current analyses present results of running ductile fracture propagation in high strength X100 line pipe steels under the influence of anisotropy. Mechanical anisotropy is commonly available in pipe products as a result of the manufacturing process, especially, those subjected to hot/cold-worked deformation. The outcomes of the present analyses show that its effect on the behavior of running ductile fracture in cracked pipes undergoing depressurization is meaningful. For instance, the Crack-Tip Opening Angle (CTOA) not only exhibits a strong dependence to the pipe's diameter size, but also to the material's anisotropy nature when compared to a hypothetical isotropic material. Moreover, laboratory scale tests such as those performed on Battelle Drop Weight Tear (BDWT) samples provide useful information about initiation of ductile crack propagation when the anisotropy features are taken into account in the material description.
In this study, the use of dry end milling of carbon fiber reinforced plastics (CFRP) as surface pretreatment for high-strength (structural) adhesive bonding was investigated. Surfaces were pretreated using different milling parameters; subsequently, they were adhesively bonded and tested. In comparison with sanding and other industrial standard pretreatment methods, the measured adhesive strength was significantly lower. Detailed surface investigations utilizing field-emission scanning electron microscopy could identify two major effects for lower adhesion strength. Intralaminar damages and microparticle residues on the created surface reduced the strength of the CFRP adhesive joints. This eventually explains results from investigations on milling pretreated repairs. By application of power ultrasound cleaning equipment and coating with low viscosity epoxy primers, the authors showed a way to overcome the discovered drawbacks and to improve bond strength significantly. Surface roughness measurements showed that the arithmetical mean roughness R(a)can be used as an effective value for assessment of mechanical pretreated CFRP surfaces as well as for the quality of necessarily following cleaning processes.
The use of non-conventional materials is nowadays of much interest in scientific community. Magneto-rheological elastomers are hybrid materials, which in presence of magnetic fields state a change in their mechanical properties. They are composed by an elastomeric matrix with embedded magnetic particles. One of the most attractive features of these materials is that as soon as the magnetic field is removed from the material, the original mechanical properties are completely recovered, with negligible differences in comparison to the original state. This paper focuses on the study of magnetic characteristics of these smart materials, such as relative permeability and demagnetizing factors, for samples with different volume concentration of ferromagnetic particles.