Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Now showing 1 - 10 of 165
  • Publication
    Additive Manufacturing enabling advanced tool, die and mold making. Market and technology report 2022
    (Fraunhofer IPK, 2024)
    Uhlmann, Eckart
    ;
    Polte, Julian
    ;
    Domingos, David Carlos
    ;
    Neuwald, Tobias
    ;
    Fasselt, Janek Maria
    ;
    Reis de Ascencao, Gustavo
    ;
    Baumgarten, Jeannette
    This international market and technology report is part of the activities of Fraunhofer IPK within FERA and presents a state of the art assessment regarding the adoption of Additive Manufacturing in industrial applications for tools, dies molds in Brazil and Germany.
  • Publication
    Nachhaltige Reinigung und Präparation
    ( 2024)
    Uhlmann, Eckart
    ;
    Polte, Julian
    ;
    Burgdorf, Philipp
    ;
    Reder, Waldemar
    In der Fertigungstechnik lautet aktuell die Devise, innovative Wege für mehr Nachhaltigkeit zu entdecken. Für industrielle Reinigungsprozesse ist das CO2-Strahlen auf dem Vormarsch - im Beitrag wird beschrieben, warum.
  • Publication
    Semi-automatic process control for efficient refurbishment of turbine blades
    ( 2023-06-16)
    Uhlmann, Eckart
    ;
    Polte, Julian
    ;
    Mühlich, Christopher
    ;
    Mönchinger, Stephan
    ;
    Ebrahimi, Puya
    The refurbishment of turbine blades requires the precise removal of damaged surface coatings. In manufacturing companies, this usually involves time-consuming activities such as detecting residual coatings and adapting process settings to varying turbine blade geometries. The use of automated systems therefore opens up opportunities to improve the efficiency of turbine blade refurbishment processes by replacing manual tasks. This paper presents an conceptual approach for a semi-automatic decoating process of turbine blades that integrates abrasive blasting technology into a closed loop process control system. The experimental setup consists of a robot for guiding the turbine blade in a blast machine and a nozzle system for local removal of residual coatings using abrasive material. Based on image processing the residual coatings of a turbine blade are labeled by a neural network and mapped to a 3D model of the turbine blade, which is used by a software control system to coordinate the decoating process. Using a prototype setup this paper investigates the applicability of the proposed approach and evaluates its feasibility.
  • Publication
    Smarte Überwachung elektrischer Großantriebe
    ( 2023)
    Geisert, Claudio
    ;
    Polte, Julian
    ;
    Uhlmann, Eckart
    ;
    Rauch, Hartmut
    ;
    Brach, Karsten
    Die Nutzung von Digitalisierungstechnologien im Kontext von Industrie 4.0 bietet insbesondere für den gesamten Bereich der Wartung und Instandhaltung von elektrischen Großantrieben großes Potenzial zur Schaffung innovativer Serviceangebote. Durch erweiterte Sensorik im elektrischen Antrieb und Intelligenz in der Verarbeitung und Analyse von Daten im Betrieb von Anlagen, kann eine vorausschauende Instandhaltungsstrategie eingeführt werden, die eine höhere Verfügbarkeit der Anlagen ermöglicht und gleichzeitig den Aufwand für Instandhaltungseinsätze reduziert. Um diese Potenziale im Servicegeschäft elektrischer Großantriebe zu erschließen, wird in diesem Beitrag ein hypothesengetriebener Ansatz zur Zustandsüberwachung beschrieben.
  • Publication
    Enabling of Automatically Generation of Cutting Paths for Three-Dimensional Pre-Contouring with Waterjet Trimming
    ( 2023)
    Reder, Waldemar
    ;
    Uhlmann, Eckart
    Abrasive Water Injector Jet Cutting (AWIJC) is a flexible machining process for manufacturing high-performance materials, such as titan-and nickel-base-alloys. Due to the low ductility and thermal conductivity of these materials, conventional machining is struggling with high tool costs and wear. The tool wear in AWIJC is independent of the machined material, and the process has the potential to provide a cost-efficient solution in machining high-performance materials. Trimming, a near-net-shape pre-contouring with multi-stage AWIJC, requires a detailed knowledge of cutting paths for all steps in advance. In order to enable a geometrical flexible manufacturing process, an automatically cutting path generation is necessary. This article presents an application developed with NX Open using Visual Basic. The application TrimCAD is able to provide all necessary geometries for trimming based on the geometries of initial and finished parts. Furthermore, it is possible to adjust the number of cuts and the degree of pre-contouring. All geometries are automatically exported as a standardized three-dimensional STEP-file. The STEP-geometries can be processed to the CAM-processor of the waterjet machine. TrimCAD is an innovative possibility to machine three-dimensional parts made of high-performance materials.
  • Publication
    Cooling Capacity of Oil-in-Water Emulsion under wet Machining Conditions
    ( 2023)
    Nabbout, Kaissar
    ;
    Sommerfeld, Martin
    ;
    Barth, Enrico
    ;
    Uhlmann, Eckart
    ;
    Bock-Marbach, Benjamin
    ;
    Kuhnert, Jörg
    Many industrial machining operations are carried out under wet machining conditions. Modelling and simulating fluid-structure-interactions and conjugate heat transfer are still a challenge nowadays. In this paper, temperature dependent heat transfer coefficients (HTC) h(T) are experimentally estimated for wet machining-like conditions in a jet cooling experiment. The transient temperature is thereby used to solve an Inverse Heat Transfer Problem for HTC function estimation. Determined HTC are applied as input in related jet cooling simulation using the Finite-Pointset-Method (FPM) to validate the modeling approach. Additionally, wet cutting simulations numerically highlight the influence of determined HTC h(T) on turning.
  • Publication
    Edge Computing Software für den Zerspanungsprozess
    ( 2023)
    Uhlmann, Eckart
    ;
    Hocke, Toni
    ;
    Heper, Martin
    ;
    Polte, Mitchel
    In aktuellen Forschungsprojekten entwickeln Forscher des Instituts für Werkzeugmaschinen und Fabrikbetrieb (IWF) Open-Source-Software für Edge Devices. Für die Auslegung der Fertigungsprozesse wird neben den ingenieurwissenschaftlichen Themen auch exemplarisch die Auslegung einer entwickelten Auswerteelektronik inklusive der Softwarebereitstellung adressiert. Der interdisziplinäre Ansatz, einschließlich der Softwarebereitstellung, wird exemplarisch an einem DFG-Projekt zur Prozessüberwachung bei der Ultrapräzisionsdrehbearbeitung diskutiert.
  • Publication
    Echtzeit-Energieüberwachung in der Funkenerosion
    ( 2023)
    Uhlmann, Eckart
    ;
    Polte, Mitchel
    ;
    Yabroudi, Sami
    ;
    Thißen, Kai
    ;
    Penske, Wilhelm
    Ein großes Optimierungspotenzial der Funkenerosion liegt in den Energien der einzelnen Entladungen verborgen. Eine vektorielle Bestimmung der Entladedauern und die darauf basierende Energieberechnung sowie Klassifizierung erlauben es, die Entladeenergien, Entladungsarten und -dauern in Echtzeit zu überwachen und zu analysieren. Möglich wird dies durch ein Multiprocessing-Erzeuger-Verbraucher-Schema, welches überdies eine Visualisierung und Auswertung der Messdaten erlaubt.
  • Publication
    Diamond slide burnishing for the finishing of electrical discharge machined surfaces
    ( 2022)
    Uhlmann, Eckart
    ;
    Polte, Mitchel
    ;
    Yabroudi, Sami
    ;
    Waiblinger, N.
    Electrical discharge machining (EDM) represents a key manufacturing technology in a broad range of industries, e. g. aerospace, automotive and mould making. Current industrial and scientific relevant challenges are long machining times to achieve the surface roughness values needed, excessive tool electrode wear and the related huge number of tool electrodes needed. At state of the art, the challenges mentioned strongly limit the economic efficiency of precision EDM processes. To overcome these major challenges, the substitution of time consuming EDM polishing processes by diamond slide burnishing (DSB) shows great potential. During the process, a monocrystalline spherical diamond burnishing tool is moved along the surface of the workpiece with a defined process force. In this way the surface is specifically compressed and roughness peaks are smoothed. Within this work the applicability of diamond slide burnishing for the finishing of electrical discharge machined surfaces was investigated. For this purpose, three VDI grades with different surface roughness values were subsequently machined by DSB. The results show that the surfaces with different initial surface conditions can be successfully finished by DSB. The surface roughness of VDI grade 30 is identified as an upper limit for the surface preparation by EDM. A significant improvement of the surface roughness Ra by 93 % and a reduction of the processing time by 40 % could be achieved by the post-processing using DSB. Therefore, the new process chain presented shows great potential for being used in the field of tool and mould making and especially for the production of injection moulds.
  • Publication
    Characterization and investigation of binderless nanopolycrystalline diamond turning tools for precision machining
    ( 2022)
    Uhlmann, Eckart
    ;
    Sturm, Heinz
    ;
    Polte, Mitchel
    ;
    Hocke, T.
    ;
    Polte, C.
    ;
    Polte, Julian
    Cemented carbide is used in a wide range of industrial applications as a wear-resistant material, e.g. in mould making and forming industry. At state of the art, the machining of cemented carbide is severely limited because of the hardness, high strength and the resulting wear resistance of the material. Due to the brittle-hard character cemented carbide materials suffer from surface cracks during the machining. The brittle-hard character and the related phenomena result in high tool wear. A promising approach for the machining of cemented carbide is the use of the novel cutting material binderless nanopolycrystalline diamond (NPD) with a dedicated cutting edge design. Within this work, laser machined tools with a corner radius of rε = 400 µm are fully characterized, investigated by Raman spectroscopy regarding the condition of the diamond and applied for first cutting experiments. Cutting investigations were carried out using specimens with a tungsten carbide content of cC = 88 %, a cobalt content of cCo= 12 % and a grain size of dg= 0.5 µm. Prior to these investigations, the condition of the diamonds and possible changes due to the lasered cutting edges were examined by Raman spectroscopy. During the cutting investigations, the brittle-ductile transition as well as the minimum chip thickness were identified by scratching tests. It could be shown that a hydrostatic stress state can be used to achieve ductile chip formation using cemented carbide as workpiece material.