Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Studie zur Stärkung der Holzbauwirtschaft in der Metropolregion Berlin-Brandenburg

2023 , Kohl, Holger , Bunschoten, Raoul , Oertwig, Nicole , Kulick, Christian , Karl, Moritz Maria , Blackburn, Phoebe , Kohl, Holger

Berlin verfolgt das Ziel, sich bis zum Jahr 2050 zu einer klimaneutralen Stadt zu entwickeln: Im Vergleich zur Gesamtsumme der CO2-Emissionen des Jahres 1990, sollen diese bis 2030 um mindestens 60 Prozent und bis zum Jahr 2050 um mindestens 85 Prozent verringert werden. Fast ein Drittel der CO2-Emissionen in Deutschland kann dem Gebäudebereich zugerechnet werden. Einen enormen Hebel zur Verbesserung der Klimabilanz bietet der konsequente Einsatz von Baumaterialien auf Basis nachwachsender Rohstoffe. Insbesondere der Baustoff Holz kann für die Metropolregion Berlin-Brandenburg eine zentrale Stellung zur Erreichung der Klimaziele einnehmen. Hierzu wurde bereits im Frühjahr 2021, in der Vorhabensliste1 des Strategischen Gesamtrahmens Hauptstadtregion, eine regionale Holzbau-Offensive festgehalten. Diese hat zum Ziel, die Region Berlin-Brandenburg zu einer Region des Holzbaus zu entwickeln. Damit die holzbasierte Transformation des Bauens in der Hauptstadtregion nachhaltig gelingt, ist insbesondere eine starke kreislaufwirtschaftsbasierte regionale Holzbauwirtschaft von Bedeutung.

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Investigation of liquid metal embrittlement avoidance strategies for dual phase steels via electro-thermomechanical finite element simulation

2022-06 , Biegler, Max , Böhne, Christoph , Seitz, Georg , Meschut, Gerson , Rethmeier, Michael

Modern advanced high-strength steel (AHSS) sheets used in automotive body construction are mostly zinc coated for corrosion resistance. The presence of zinc can cause cracking in steels due to liquid metal embrittlement (LME) during resistance spot welding (RSW). In combination with factors such as tensile strains, liquid zinc can lead to the formation of brittle, intergranular cracks in the weld and heat affected zone. While practical investigations to mitigate LME occurrence exist, the reason why a certain parameter might cause or prevent LME is often unknown. Numerical resistance spot welding simulation can visualize the underlying stresses, strains and temperatures during the welding process and investigate experimentally unmeasurable phenomena. In this work, a 3-dimensional electro-thermomechanical finite element approach is used to assess and investigate the critical parameters leading to LME occurrence. Experimentally observed crack sizes are correlated with the corresponding local strain rates and temperature exposure durations in the simulation. With this data, a map of LME occurrence over driving influence factors is drafted and discussed for effectiveness.

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Learning Demonstrator for Anomaly Detection in Distributed Energy Generation

2022-04-07 , Pelchen, Timo , Thiele, Gregor , Vick, Axel , Radke, Marcel , Schade, David , Krüger, Jörg

Machine learning based anomaly detection methods on process data can be used to secure critical infrastructure. The design and installation of these methods require detailed understanding of both the facilities and the machine learning methods. Therefore, they are mostly incomprehensible for non-experts and thus acting as a barrier hindering the fast spread of such technologies. This article presents the systematic development of a demonstrator which enables presentations of anomaly detection on the example of a simulated wind farm. The specially designed user-interface allows a comprehensive experience. This article documents the use of the demonstrator for experts experienced in energy systems which are interested in the application of machine learning algorithms.

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Methodik zur modellbasierten Systemarchitekturdefinition von Smart-circular Product-Service Systems

2022 , Halstenberg, Friedrich Andreas

Induziert durch Digitalisierung und Servitisierung bieten Unternehmen in zunehmendem Maße Systeme aus vernetzten mechatronischen Produkten, Software und Dienstleistungen an: sogenannte Smart-circular Product Service Systems (Smart-circular PSS). Ungeklärt ist bislang, wie Teams bei der Entwicklung von Smart-circular PSS sachgerecht methodisch unterstützt werden können. Diese Arbeit begegnet diesen Beobachtungen mit der Forschungshypothese, dass sich Systemarchitekturen von Smart-circular PSS durch geeignete Methoden des Modellbasierten Systems Engineerings (MBSE) so entwerfen lassen, dass die Systeme effektiv und effizient zu einer CE beitragen. Aufbauend auf gewonnenen Erkenntnissen wurde die Methodik zur Definition von Smart-circular PSS-Systemarchitekturen (MESSIAH) entwickelt, die Entwicklungsteams bei der Konzeptionierung von Smart-circular PSS unterstützt. Die Methode beinhaltet eine Modellierungsgenerik, eine gerichtete Methode sowie einen Baukasten zum schnellen Prototypisieren von Services. MESSIAH wurde anhand von fünf Studien evaluiert und erprobt.

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Resource efficient production of car body parts - implementation of digital twins across process chains

2022-09-21 , Weber, Joshua , Lemke, Josefine , Sunderkoetter, Christina , Haase, Patrick , Hoefemann, Matthias , Joos, Paul , Merklein, Marion

Sustainable production and environmentally friendly life cycle of every car is a main goal in the automotive industry. But there is a conflict between the rising demands of crash safety, the addition of components due to electric mobility and the reduction of weight. Car body parts can increase the crash safety and have a high lightweight construction potential. Especially tailor welded blanks made of multi-phase steel with a tensile strength of 1000 MPa, which are not established in car body parts, have the potential to improve the crash safety, save resources and lower the weight. The main challenge in the manufacturing of tailor welded blanks made of highest strength steel is the complex and expensive development. Due to the heat input and geometrical changes, the welding process affects the forming properties of the metal sheets. To evaluate the influence from different welding parameters to the forming process, a high number of expensive experiments must be repeated. This includes welding and forming parameter changes as well as adjustments to the forming tool. In order to make the development and manufacturing of tailor welded blanks made of highest strength steels more resource efficient, this work discusses the development and implementation of a digital and bidirectional twin in an industry-oriented environment. The objective is to demonstrate the data management based on the sheet metal properties, the change of properties due to laser welding simulated in Simufact Welding and the final forming process in AutoForm Forming. Additionally, the concept of a life cycle assessment of a tailor welded blank during these steps is developed. As summary the challenges, limitations, and improvements of the digital and bidirectional twin as replacement or, in addition to a consisting development process are discussed.

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Integrated weld preparation designs for the joining of L-PBF and conventional components via TIG welding

2022-04-18 , Geisen, Ole , Müller, Vinzenz , Graf, Benjamin , Rethmeier, Michael

Laser powder bed fusion (L-PBF) of entire assemblies is not typically practical for technical and economic reasons. The build size limitations and high production costs of L-PBF make it competitive for smaller, highly complex components, while the less complex elements of an assembly are manufactured conventionally. This leads to scenarios that use L-PBF only where it's beneficial, and it require an integration and joining to form the final product. For example, L-PBF combustion swirlers are welded onto cast parts to produce combustion systems for stationary gas turbines. Today, the welding process requires complex welding fixtures and tack welds to ensure the correct alignment and positioning of the parts for repeatable weld results. In this paper, L-PBF and milled weld preparations are presented as a way to simplify the Tungsten inert gas (TIG) welding of rotationally symmetrical geometries using integrated features for alignment and fixation. Pipe specimens with the proposed designs are manufactured in Inconel 625 using L-PBF and milling. The pipe assembly is tested and TIG welding is performed for validation. 3D scans of the pipes before and after welding are evaluated, and the weld quality is examined via metallography and computed tomography (CT) scans. All welds produced in this study passed the highest evaluation group B according to DIN 5817. Thanks to good component alignment, safe handling, and a stable welding process, the developed designs eliminate the need for part-specific fixtures, simplify the process chain, and increase the process reliability. The results are applicable to a wide range of components with similar requirements.

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Skalierbare Herstellung von ATMPs

2022 , Gebken, Natalie , Horbelt, Jessica , Kleine-Wechelmann, Sarah , Ort, Thomas , Puls, Sebastian , Schandar, Markus , Traube, Andreas , Biermann, Ferdinand , Brandstätter, Tobias Claus , Gräfe, Stefan , Herbst, Laura , König, Niels , Schmitt, Robert , Ackermann, Heiner , Diessel, Erik , Lengen, Rolf Hendrik van , Schmidt, Andreas , Braun, Dennis , Hunger, Sandra , Werner, Michael , Boskovic, Dusan , Mendl, Alexander , Graumann, Tobias , Lachmann, Kristina , Mann, Annika , Brehmer, Annika , Dürre, Gregor , Hein, Christoph , Blache, Ulrich , Dluczek, Sarah , Dünkel, Anna , Franz, Paul , Fricke, Stephan , Tradler, Thomas

Die Entwicklung von Arzneimitteln für neuartige Therapien (ATMPs; Advanced Therapy Medicinal Products) schreitet schnell voran. Erste Produkte haben bereits die Marktzulassung erhalten und sind kommerziell erhältlich. Ihre Produktion ist jedoch von komplexen manuellen Abläufen, hochspezialisierten Geräten und den damit verbundenen hohen Produktionskosten geprägt. Aufgrund der Neuartigkeit und der hohen Komplexität bei der Produktion kann das volle klinische Potential von ATMPs in Zukunft unter den bestehenden Produktionsbedingungen nicht ausgeschöpft werden. Darüber hinaus nehmen die am Markt zugelassenen Produkte und die klinischen Anwendungsgebiete von ATMPs stetig zu, was langfristig nicht nur zu einem Engpass in der Produktion, sondern auch zu einer hohen finanziellen Belastung des Gesundheitssystems führen wird. Um die Herstellkosten von ATMPs zu senken und sie vielen Patientinnen und Patienten zur Verfügung stellen zu können, sind neue Konzepte entlang der gesamten Wertschöpfungskette erforderlich. Dafür muss die Produktion insbesondere stärker automatisiert und digitalisiert werden. Unterschiedliche Konzepte sind hier vielversprechend für eine vollautomatisierte Produktion, im Sinne einer vollintegrierten Automatisierung oder eines modularen Aufbaus der Produktionsumgebung. Die Implementierung dieser Konzepte setzt neue Entwicklungen voraus, von der Entnahme der Zellen bei der Spenderin oder beim Spender über die Produktionstechnologien an sich bis hin zur finalen Formulierung und Abfüllung des Produkts. Neben Änderungen im Bereich der Hardware werden auch neue Softwarelösungen notwendig, beispielsweise zur Planung und Auswahl geeigneter Produktionsszenarien. Auch für die eigentliche Produktion von ATMPs und die damit verbundenen Daten müssen zukünftig neue Technologien, wie bspw. integrierte Prozesskontrollen, die Prozessbegleitung mittels Digitalem Zwilling oder die Analyse sowie Prozesssteuerung mittels Künstlicher Intelligenz (KI) berücksichtigt werden, um das volle Automatisierungspotential ausschöpfen zu können.

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Result quality evaluation of Directed Energy Deposition Additive Manufacturing simulations with progressive simplification of transient heat-source motion

2022-09-05 , Biegler, Max , Elsner, Beatrix A.M. , Neubauer, Ingo , Lemke, Josefine , Rethmeier, Michael

Directed Energy Deposition (DED) additive manufacturing has recently been adopted in the industry for the build-up of structural components with weld lengths up to kilometers. As with all welding processes, DED suffers from thermal distortion, causing loss of dimensional accuracy and risk of cracking. Currently, process optimization with objective to minimize distortion requires expensive experimental trial-and-error. With numerical simulation of the DED process, this distortion compensation can be performed virtually, significantly reducing experimental trials. Although such approaches are generally available, their widespread adoption is currently being hampered by long computational times for large builds. This work presents a novel approach to reduce the calculation time by a simplification of the transient heat-source motion. This approach is assessed in terms of result accuracy for an industrial-scale component by progressively reducing the resolution of the heat-source motion. Calculation times as well as distortions in comparison to experimental trials are investigated.

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Quality Prediction in Directed Energy Deposition Using Artificial Neural Networks Based on Process Signals

2022-04-14 , Marko, Angelina , Bähring, Stefan , Raute, Maximilian Julius , Biegler, Max , Rethmeier, Michael

The Directed Energy Deposition process is used in a wide range of applications including the repair, coating or modification of existing structures and the additive manufacturing of individual parts. As the process is frequently applied in the aerospace industry, the requirements for quality assurance are extremely high. Therefore, more and more sensor systems are being implemented for process monitoring. To evaluate the generated data, suitable methods must be developed. A solution, in this context, was the application of artificial neural networks (ANNs). This article demonstrates how measurement data can be used as input data for ANNs. The measurement data were generated using a pyrometer, an emission spectrometer, a camera (Charge-Coupled Device) and a laser scanner. First, a concept for the extraction of relevant features from dynamic measurement data series was presented. The developed method was then applied to generate a data set for the quality prediction of various geometries, including weld beads, coatings and cubes. The results were compared to ANNs trained with process parameters such as laser power, scan speed and powder mass flow. It was shown that the use of measurement data provides additional value. Neural networks trained with measurement data achieve significantly higher prediction accuracy, especially for more complex geometries.

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Modellieren von Widerstandspunktschweissungen in FE

2022 , Seitz, Georg

In der Veröffentlichung wird anwendungsbezogen die Simulation von Widerstandpunktschweißungen in FEA-Programmen erklärt. Hierbei wird insbesondere der Nutzen für den praxisorientieren Schweißingenieur/Produktionsplaner erläutert und wie dieser die Schweißstruktursimulation nutzen kann, um Schweißverzug vorherzusagen und diesen zu minimieren.

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