Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Fully coupled wet cylindrical turning simulation using the Finite-Pointset-Method
    ( 2021)
    Uhlmann, Eckart
    ;
    Barth, Enrico
    ;
    Quellhorst, Alexander
    ;
    Seifarth, Tobias
    ;
    Kuhnert, Jörg
    ;
    Nabbout, Kaissar
    ;
    Sommerfeld, Martin
    In industrial machining operations, many turning processes are carried out under wet conditions. In contrast, most simulation tools are only suitable for dry cutting processes due to challenges of modeling fluid-structure-interactions (FSI). In this paper, a wet, fully coupled cutting simulation using the Finite-Pointset-Method (FPM) is presented and validated for industrially relevant cylindrical turning. To facilitate the required reduction of the calculation effort, different routines like adaptive numerical discretization are applied. The results indicate different cutting fluid effects like evaporation areas around the chip.
  • Publication
    Data for a simulation of metal cutting with cutting fluid using the Finite-Pointset-Method
    ( 2021)
    Uhlmann, Eckart
    ;
    Barth, Enrico
    ;
    Seifarth, Tobias
    ;
    Höchel, Maximilian
    ;
    Kuhnert, Jörg
    ;
    Eisenträger, Almut
    The measurement and simulation data, their preparation and the simulation setup published in this co-submission are related to the article ""Simulation of metal cutting with cutting fluid using the Finite-Pointset-Method"". Wet and dry turning experiments were conducted at the Institute for Machine Tools and Factory Management(IWF), Berlin, Germany. Required adaptions of the used software MESHFREE were performed at Fraunhofer ITWM, Kaiserslautern, Germany. Both institutes collaboratively developed and validated the orthogonal cutting simulation model using the Finite-Pointset-Method (FPM). In this paper all measurement and simulation data and their preparation methods are presented in detail. This includes the preparation methods of process forces, analysis of chip morphology images as well as measured contact lengths on tool rake faces. Moreover, the experimental and simulation data are provided at the Mendeley Data repository. Hence the reader can use the data for own validations and analysis. Furthermore, the used simulation model files are completely published at the Mendeley Data repository. It allows the reader to retrace all settings. In addition, this enables to repeat the simulations and to simulate other process parameter combinations according to own interests.
  • Publication
    Optimization with the evolution strategy by example of electrical-discharge drilling
    ( 2020)
    Streckenbach, Jan
    ;
    Koref, Ivan Santibáñez
    ;
    Rechenberg, Ingo
    ;
    Uhlmann, Eckart
    A key challenge in electrical discharge machining (EDM) is to find a suitable combination out of numerous process parameters. Any changes concerning the electrode materials or geometries require newly optimized technologies. These technologies are to be developed from a considerable number of experiments which must be carried out by an experienced operator. This paper presents a new method of finding the optimal set of parameters. Here, the performance of the evolution strategy (ES), a stochastic, metaheuristic optimization method, is investigated. It offers the great advantage of finding solutions, even with little knowledge of system behaviour. The method involved a randomized and a derandomized ES, based on a non-elitist (m,l)-ES with one parent and four children. The two ES were initialized from an unfavourable starting point (A) and from a favourable starting point (B) to investigate their effectiveness. It could be demonstrated that starting from the unfavourable starting point A the erosion duration tero could be reduced by a maximum of 77% with a slightly smaller linear wear of the tool electrode DlE after 40 trials.
  • Publication
    Decision-making support for sustainable product creation
    ( 2012)
    Inoue, Masato
    ;
    Lindow, Kai
    ;
    Stark, Reiner
    ;
    Tanaka, Kenji
    ;
    Nahm, Yoon-Eui
    ;
    Ishikawa, Haruo
    A satisfactory multiobjective design that incorporates physical performance as well as sustainability is necessary from a global environmental protection perspective. For obtaining sustainable lifecycles, decision making in the early phases of the design process, considering multiple sources of uncertainty, is important. Previously, we proposed a preference set-based design (PSD) by Inoue et al. (2010) [16] method, which enables a flexible and robust design under various sources of uncertainty while capturing the designers preference based on his/her knowledge or experience. The present study focuses on a decision-making support for sustainable product creation in the early phases of the design process considering the various design uncertainties. We investigate different officially accepted sustainability indicators and identify the ones that are related to the product development process by considering the physical performance and sustainability of the products concurrently. Thereafter, the proposed method is applied to a multiobjective design problem. This paper discusses the applicability of PSD as a decision-making support method for sustainable development using the design of an alternator as an example.
  • Publication
    Entwicklung der netzfreien Finite-Pointset-Methode für die Zerspansimulation
    ( 2011)
    Uhlmann, E.
    ;
    Gerstenberger, R.
    ;
    Schäfer, M.
    ;
    Kuhnert, J.
    Aktuelle Programme für die Finite-Elemente-Simulation von Zerspanprozessen verwenden Neuvernetzungsprozeduren, um die Trennung von Span und Grundwerkstoff abzubilden und die in den Scherzonen auftretenden großen Elementverzerrungen zu korrigieren. Diese Prozeduren schränken jedoch die Abbildungsgenauigkeit auf Grund von Interpolationsverlusten ein. Eine netzfreie Simulationsmethode ohne Neuvernetzungsprozeduren kann daher für die Zerspansimulation vorteilhaft sein. Im Rahmen der Weiterentwicklung der netzfreien Finite-Pointset-Methode (FPM) für die Zerspansimulation wurden ein Materialmodell für metallische Werkstoffe implementiert, Spanbildungssimulationen mit unterschiedlichen Werkstoffen durchgeführt und erste Schritte zur Darstellung des Kühlschmierstoffs in der Zerspansimulation unternommen.
  • Publication
    InViS - Integrierter Virtueller Schiffbau
    ( 2004)
    Lukas, U. von
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    Schulte, G.
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    Hayka, H.
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    Scheller, M.
    ;
    Wolf, A.
    Der Beitrag stellt wesentliche Ergebnisse des BMBF-Projekts InViS - Integrierter Virtueller Schiffbau vor. Hierzu zählen das als XML-Schema codierte Datenmodell, die offene Integrationsplattform sowie verschiedene darauf aufbauende Komponenten für Telekooperation, VR-Präsentation, Simulation und Anbindung von CAD-Systemen. Die Projektergebnisse werden im Kontext des Virtuellen Maschinenraums in zwei Anwendungsszenarien evaluiert und verdeutlichen das Potential des integrativen Ansatzes zur Unterstützung durchgängiger Prozessketten.
  • Publication
    A novel disassembly tool with screwnail endeffectors
    ( 2002)
    Seliger, G.
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    Rebafka, U.
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    Stenzel, A.
    ;
    Zuo, B.-R.
  • Publication
    Practical applications of neural networks in texture analysis
    ( 1996)
    Biebelmann, E.
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    Köppen, M.
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    Nickolay, B.
  • Publication
    Sewage pipe image segmentation using a neural based architecture
    ( 1996)
    Ruiz del Solar, J.
    ;
    Köppen, M.
  • Publication
    Integrated electromechanical design
    ( 1996)
    Hayka, H.
    ;
    Morche, I.