Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Conceptual Introduction of required development capabilities for Model-Based Systems Engineering
    ( 2021)
    Manoury, Marvin Michael
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    Schmidt, Simon
    ;
    Zimmermann, Thomas C.
    ;
    Stark, Rainer
    In the last years, multiple tools and methodologies have emerged that try to support the engineers to conduct Model Based Systems Engineering (MBSE). Nevertheless, the tools are usually bound to a certain methodology, which often requires sequential steps instead of supporting the iterative character of modern product development. In this paper, we conceptually introduce the development capabilities of the 5D model for MBSE as a convenient way to cover all relevant aspects of MBSE in an iterative way while being open to methodology and tool choice.
  • Publication
    Towards an AI-Enhanced Circular Economy. AI-enhanced identification, inspection and sorting for reverse logistics
    ( 2020)
    Schlüter, Marian
    In terms of circular economy, remanufacturing ensures a high level of value recovery. After each life-cycle used products are returned to a remanufacturer for identification, inspection, sorting and reprocessing, ensuring the required quality for a next life cycle. This talk presents the project EIBA, funded by the German Federal Ministry of Education and Research, in which concepts to improve identification, inspection and sorting are developed and implemented by enhancing the sorting stations with sensor technology and AI on image and business data. First results show promising progress for AI-based visual recognition of used automotive components, also referred to as "cores".
  • Publication
    What dynamics should impedance-controlled robots render?
    ( 2019)
    Haninger, Kevin
    ;
    Surdilovic, Dragoljub
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    Bastidas Cruz, Arturo
    While impedance control is the standard framework for physically interactive robots, the design choice of what dynamics should be rendered requires additional information (assumptions on environment, in-situ data). The range of dynamics which can be rendered by a robot is informed by its mechatronic design (actuators, physical compliance, innerloop control), and these mechanical design decisions must be made in advance. How can a mechatronic design be evaluated when the system objectives and environment dynamics are not quantified? This paper presents performance metrics proposed for pHRI in literature, and seeks to move towards a unified methodology for mechatronic design on interactive robots: supporting potential performance and safety over a set of environments.
  • Publication
    Herausforderungen in der Mikrozerspanung
    ( 2019)
    Kuche, Yves
    ;
    Eckert, Udo
    Die Mikrozerspanung gewinnt aufgrund der wachsenden Märkte für Mikrokomponenten, Präzisionsbauteile und Bauteile mit Toleranzen im einstelligen Mikrometerbereich zunehmend an Bedeutung. Verfahren wie das Mikrodrehen, Mikrofräsen und Mikrobohren ermöglichen dabei die Fertigung von Bauteilen mit einer großen Geometriekomplexität in einem breiten Werkstoffspektrum, wodurch die Verfahren in Anwendungsfeldern wie dem Werkzeug- und Formenbau, der Mikrosystemtechnik, der Medizintechnik und der Feinwerktechnik nicht mehr wegzudenken sind. Bei der Mikrozerspanung nimmt der Einfluss des Schneidstoff- und Werkstückwerkstoffs, der Werkzeugmakro- und Werkzeugmikrogeometrie sowie der Prozesstechnologie im Vergleich zur Makrozerspanung deutlich zu. Grund dafür sind die im Vergleich zur Makrozerspanung geringeren Zustellungen und Schnitttiefen, welche aus den kleineren Werkzeugdimensionen resultieren. Weiterhin nimmt beispielsweise beim Mikrofräsen der Einfluss von Schwingungen erheblich zu und kann zu einem inhomogenen Prozess mit raschen Werkzeugversagen und einer schlechten Bauteilqualität resultieren. Innerhalb des Vortrags werden die grundlegenden Einflussgrößen bei der Mikrozerspanung erläutert und anhand von Beispielen und Untersuchungsergebnissen veranschaulicht. Durch aktuelle Ergebnisse aus der Grundlagen- sowie anwendungsorientierten Forschung werden weiterhin Einblicke in aktuelle Entwicklungsthemen gegeben, welche gemeinsam mit dem Fachpublikum diskutiert werden können. Diese beinhalten beispielsweise Erkenntnisse zum Einfluss der Werkzeugmikrogeometrie, Anforderungen bei der Zerspanung verschiedener Werkstoffe, dem Schwingungseinfluss sowie deren Analyse bei der Mikrozerspanung und die Potentiale verschiedener Schneidstoffe.
  • Publication
    Avoidance of End Crater Imperfections at High-Power Laser Beam Welding of Closed Circumferential Welds
    ( 2019)
    Gook, Sergej
    ;
    Üstündag, Ömer
    ;
    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    The present work deals with the development of a strategy for the prevention of end crater defects in high-power laser welding of thick-walled circumferential welds. A series of experiments were performed to understand the influence of the welding parameters on the formation of the imperfections such as pores, cracks, excessive root-side drop-through and shrinkage cavities in the overlap area. An abrupt switch-out of the laser power while closing the circumferential weld leads to a formation of a hole which passes through the whole welded material thickness. A laser power ramp causes solidification cracks which are initiated on the transition from full-penetration mode to partial penetration. Strategies with a reduction of the welding speed shows a creation of inadmissible root sagging. Defocusing the laser beam led to promising results in terms of avoiding end crater imperfections. Cracks and pores could be effectively avoided by using defocusing techniques. A strategy for avoiding of end crater defects was tested on flat specimens of steel grade S355J2 with a wall thickness of 10 mm and then transferred on the 9.5 mm thick pipe sections made of high-strength steel X100Q.
  • Publication
    A study on shielded metal arc welding of 9%Ni steel using non-conventional ferritic welding electrode for LNG facilities
    ( 2018)
    Siayah, A.
    ;
    El-Batahgy, A-M.
    ;
    Khafagi, S.
    ;
    Gumenyuk, A.
    ;
    Gook, S.
    ;
    Rethmeier, M.
    The present research work aims at clarification of the effect of the welding electrode type on the mechanical properties of SMA welded joints of 9%Ni steel plates. Properties of produced SMA welded joints were evaluated using different non-destructive and destructive investigation methods. In comparison with the conventionally used Ni-based welding electrode ENiCrMo-3 (AWS A5.11), an experimentally produced non-conventional ferritic welding electrode with 11%Ni (ENi11-Company specification) has resulted in a better combination of the mechanical properties of SMA welded joints of this steel type for critical cryogenic applications. Besides, a positive economic impact for the experimentally produced non-conventional ferritic welding electrode, due to its lower cost, could be another attractive aspect.
  • Publication
    Hybrid laser arc welding of 25 mm thick materials using electromagnetic weld pool support
    ( 2018)
    Üstündag, Ömer
    ;
    Avilov, Vjaceslav
    ;
    Gumenyuk, Andrey
    ;
    Rethmeier, Michael
    In addition to the many advantages of deep penetration, increased welding speed and a low sensitivity to manufacturing tolerances such as gap and edge offset, the hybrid laser arc welding process is used increasingly in industrial applications such as shipbuilding or pipeline manufacturing. Nonetheless, thick-walled sheets with a wall thickness of 20 mm or more are still multi-pass welded using the arc welding process, due to increased process instability by increasing laser power. Welding at reduced speed, especially in a flat position, leads to an irregular formation of the root part such as dropping. The hydrostatic pressure exceeds the surface tension, which decreases with increasing seam width. In order to prevent gravity drop-outs, the use of a melt pool support is necessary. Usual weld pool supports such as ceramic or powder supports require time-consuming mechanical detachment. The electromagnetic weld pool support system, which is described in this study, operates without contact and based on generating Lorentz forces in the weld pool. An externally applied oscillating magnetic field induces eddy currents and generates an upward directed Lorentz force, which counteracts the hydrostatic pressure. This allows single-pass welds up to 25 mm by hybrid laser arc welding process with a 20-kW fibre laser. Moreover, it is favoured by the diminished welding speed the cooling rate which leads to an improvement of the mechanical-technological properties of the seams - the lower formation of martensite in the microstructure enables better Charpy impact toughness. The electromagnetic weld pool support extends the limitation of the laser hybrid welding process in the thick sheet area. By adapting the electromagnetic weld pool support to the laser and laser hybrid welding process, the application potential of these technologies for industrial implementation can be drastically increased.