Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Methodology for a reverse engineering process chain with focus on customized segmentation and iterative closest point algorithms
    ( 2022)
    Mönchinger, Stephan
    ;
    Schröder, Robert
    ;
    Stark, Rainer
    One-off construction is characterized by a multiplicity of manual manufacturing processes whereby it is based on consistent use of digital models. Since the actual state of construction does not match the digital models without manually updating them, the authors propose a method to automatically detect deviations and reposition the model data according to reality. The first essential method is based on the ""Segmentation of Unorganized Points and Recognition of Simple Algebraic Surfaces"" presented by Vanco et al.. The second method is the customization of the iterative closest point (ICP) algorithm. The authors present the overall structure of the implemented software, based on open source and relate it to the general reverse engineering (RE) framework by Buonamici et al.. A highlight will be given on: the general architecture of the software prototype; a customized segmentation and clustering of unorganized points and recognition of simple algebraic surfaces; the deviation analysis with a customized iterative closest point (CICP) algorithm Especially in the field of one-off construction, characterized by small and medium companies, automated assessment of 3D scan data during the design process is still in its infancy. By using an open source environment progress for consistent use of digital models could be accelerated.
  • Publication
    Multiple-Wire Submerged Arc Welding of High-Strength Fine-Grained Steels
    ( 2022)
    Gook, S.
    ;
    El-Sari, Bassel
    ;
    Biegler, Max
    ;
    Rethmeier, Michael
    ;
    Lichtenthäler, F.
    ;
    Stark, M.
    Ensuring the required mechanical-technological properties of welds is a critical issue in the application of multi-wire submerged arc welding process for welding high-strength fine-grained steels. Excessive heat input is one of the main causes for microstructural zones with deteriorated mechanical properties of the welded joint, such as a reduced notched impact strength and a lower structural robustness. A process variant is proposed which reduces the weld volume as well as the heat input by adjusting the welding wire configuration as well as the energetic parameters of the arcs, while retaining the advantages of multi-wire submerged arc welding such as high process stability and production speed.
  • Publication
    Characterization of Ti-6Al-4V Fabricated by Multilayer Laser Powder-Based Directed Energy Deposition
    ( 2022)
    Ávila Calderón, Luis Alexander
    ;
    Graf, Benjamin
    ;
    Rehmer, Birgit
    ;
    Petrat, Torsten
    ;
    Skrotzki, Birgit
    ;
    Rethmeier, Michael
    Laser powder-based directed energy deposition (DED-L) is increasingly being used in additive manufacturing (AM). As AM technology, DED-L must consider specific challenges. It must achieve uniform volume growth over hundreds of layers and avoid heat buildup of the deposited material. Herein, Ti-6Al-4V is fabricated using an approach that addresses these challenges and is relevant in terms of transferability to DED-L applications in AM. The assessment of the obtained properties and the discussion of their relationship to the process conditions and resulting microstructure are presented. The quality of the manufacturing process is proven in terms of the reproducibility of properties between individual blanks and with respect to the building height. The characterization demonstrates that excellent mechanical properties are achieved at room temperature and at 400 C.
  • Publication
    Hybrid laser-arc welding of laser- and plasma-cut 20-mm-thick structural steels
    ( 2022)
    Üstündag, Ömer
    ;
    Bakir, Nasim
    ;
    Gook, Sergej
    ;
    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    It is already known that the laser beam welding (LBW) or hybrid laser-arc welding (HLAW) processes are sensitive to manufacturing tolerances such as gaps and misalignment of the edges, especially at welding of thick-walled steels due to its narrow beam diameter. Therefore, the joining parts preferably have to be milled. The study deals with the influence of the edge quality, the gap and the misalignment of edges on the weld seam quality of hybrid laser-arc welded 20-mm-thick structural steel plates which were prepared by laser and plasma cutting. Single-pass welds were conducted in butt joint configuration. An AC magnet was used as a contactless backing. It was positioned under the workpiece during the welding process to prevent sagging. The profile of the edges and the gap between the workpieces were measured before welding by a profile scanner or a digital camera, respectively. With a laser beam power of just 13.7 kW, the single-pass welds could be performed. A gap bridgeability up to 1 mm at laser-cut and 2 mm at plasma-cut samples could be reached respectively. Furthermore, a misalignment of the edges up to 2 mm could be welded in a single pass. The new findings may eliminate the need for cost and time-consuming preparation of the edges.
  • Publication
    Багатодротове дугове зварювання високоміцних дрібнозернистих сталей під флюсом
    ( 2022)
    Gook, Sergej
    ;
    El-Sari, Bassel
    ;
    Biegler, Max
    ;
    Rethmeier, Michael
    ;
    Lichtenthäler, F.
    ;
    Stark, M.
    Ensuring the required mechanical-technological properties of welds is a critical issue in the application of multi-wire submerged arc welding process for welding high-strength fine-grained steels. Excessive heat input is one of the main causes for microstructural zones with deteriorated mechanical properties of the welded joint, such as a reduced notched impact strength and a lower structural robustness. A process variant is proposed which reduces the weld volume as well as the heat input by adjusting the welding wire configuration as well as the energetic parameters of the arcs, while retaining the advantages of multi-wire submerged arc welding such as high process stability and production speed
  • Publication
    Wolframschmelzcarbidbasierte MMC-Schichten für den industriellen Einsatz im Formenbau
    ( 2022)
    Langebeck, Anika
    ;
    Jahnke, Christian
    ;
    Wünderlich, Tim
    ;
    Hein, Christoph
    ;
    Bohlen, Annika
    ;
    Uhlmann, Eckart
    Zur Steigerung der abrasiven Verschleißbeständigkeit können Oberflächen lokal mit Hartpartikeln verstärkt werden. Diese sogenannten Metal-Matrix-Composit(MMC)-Schichten können mittels Laserstrahldispergieren gefertigt und durch Mikrofräsen nachbearbeitet werden. Im hier vorgestellten Forschungsvorhaben wurde als Grundwerkstoff verwendete Aluminiumbronze (CuAl10Ni5Fe4) mit Wolframschmelzcarbid verstärkt. Der Hartpartikelgehalt kann dabei durch eine Steigerung des Pulvermassenstroms bis zur Packungsdichte des unverarbeiteten Pulvers erhöht werden. Über eine temperaturbasierte Leistungsregelung kann eine gleichbleibend homogene MMC-Schicht mit konstanter Dicke und Tiefe dispergiert werden. Durch das Mikrofräsen mit optimierten Parametern können qualitativ hochwertige MMC-Oberflächen für den industriellen Einsatz in Spritzgusswerkzeugen hergestellt werden. Dabei wurde vor allem der Zahnvorschub fz als kritischer Prozessparameter identifiziert.
  • Publication
    Effects on crack formation of additive manufactured Inconel 939 sheets during electron beam welding
    ( 2022)
    Raute, Julius
    ;
    Jokisch, Torsten
    ;
    Biegler, Max
    ;
    Rethmeier, Michael
    The potential of additive manufacturing for processing precipitation hardened nickel-base superalloys, such as Inconel 939 is considerable, but in order to fully exploit this potential, fusion welding capabilities for additive parts need to be explored. Currently, it is uncertain how the different properties from the additive manufacturing process will affect the weldability of materials susceptible to hot cracking. Therefore, this work investigates the possibility of joining additively manufactured nickel-based superalloys using electron beam welding. In particular, the influence of process parameters on crack formation is investigated. In addition, hardness measurements are performed on cross-sections of the welds. It is shown that cracks at the seam head are enhanced by welding speed and energy per unit length and correlate with the hardness of the weld metal. Cracking parallel to the weld area shows no clear dependence on the process variables that have been investigated, but is related to the hardness of the heat-affected zone.
  • Publication
    Hybrid Laser-Arc Welding of Thick-Walled, Closed, Circumferential Pipe Welds
    ( 2022)
    Üstündag, Ömer
    ;
    Bakir, Nasim
    ;
    Gook, Sergej
    ;
    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    The application of hybrid laser-arc welding (HLAW) for joining closed circumferential welds is a challenge due to the high risk of forming a defective overlap area with a shrinkage void or solidification cracks in the material thickness. A series of HLAW experiments were performed to understand the development of a faulty overlap area when closing the circumferential weld. Welding trials on flat specimens and pipe segments were supported by numerical analyses in which the thermomechanical behavior of the welds in the overlap area was investigated. Different process control strategies were tested, including variations in defocusing levels and the overlap length. The newly developed HLAW head, including laser optics with a motor-driven collimation system, made it possible to defocus the laser beam during welding without disturbing the stability of the welding process. High-level defocusing of the laser beam of more than 40 mm relative to the specimen surface with a resulting beam diameter of > 2.9 mm, and in combination with a short overlap length of 15 mm, was promising with respect to the formation of a desired cup-shaped weld profile that is resistant to solidification cracks.
  • Publication
    Automated 3D scan based CAD-repositioning for design and verification in one-off construction
    ( 2021)
    Mönchinger, S.
    ;
    Schröder, R.
    ;
    Stark, R.
    The presented engineering discipline one-off construction is characterized by a multiplicity of manual processes. As almost all modern product developments, the manufacture is based on the creation and consistent use of digital models. Quality of underlying data can vary greatly and it is not certain that digital models match the actual state of construction. This can result in the need for rework after production or installation. Especially challenging in the area of premium products, for which high quality, scarce materials are used and tight schedules are defined. If physical products are reworked, the corresponding digital models must be manually maintained. At present, attempts are being made to counteract these late adjustments by means of physical mock-ups or visual inspection of 3D scan data. Such scan data is used for automated adaptation of underlying digital models to the actual state of the physical construction. Existing Point Cloud Library functionalities were adapted and further algorithms were designed. The developed software backend was integrated into the existing software architecture. During the software development, great care was taken to ensure that the backend is based on open source content. The results show significant improvements of the data basis for the subsequent engineering activities. This will lead to a significant reduction of manual effort and rework, ensuring development cycles and even shorten delivery times. It reduces costs in the product creation process and sustainably strengthens confidence in digital models used. It has been shown that automation of design processes can have productivity-enhancing effects in one-off construction.
  • Publication
    Time-Sensitive Networking over Metropolitan Area Networks for Remote Industrial Control
    ( 2021)
    Tschöke, Simon
    ;
    Lynker, Frederic
    ;
    Buhr, Hauke
    ;
    Schreiner, Florian
    ;
    Willner, Alexander
    ;
    Vick, Axel
    ;
    Chemnitz, Moritz
    The benefits of the currently evolving IEEE Time-Sensitive Networking (TSN) standard have already been globally recognized. Whereas the application of TSN in a LAN is currently widely and globally tested, TSN in a Metropolitan Area Network (MAN) has not been a major focus until now. The possible benefits of utilizing co-located Edge Clouds in order to support multiple urban production sites with industrial realtime applications open a wide range of new business models. Therefore, we have analyzed the feasibility of transparently using PROFINET over TSN via a Dense Wavelength Division Multiplex (DWDM) link, where a machine park is controlled remotely by an Edge-based virtual Programmable Logic Controller (vPLC). As a result, we are able to setup a TSN connection over a MAN with a one-way delay of about 156.5 J.ms and a jitter of about 12 ns. This work can be extended to allow for dynamically provisioned TSN flows and multi-path Frame Replication and Elimination (FRER) for distributed hard real-time machine control and adoption to Ultra-Reliable Low-Latency Communication (URLLC) 5G campus networks.