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PublicationLife cycle analysis results for engine blisk LCA( 2024-02-05)Purpose - The aviation industry has seen consistent growth over the past few decades. To maintain its sustainability and competitiveness, it is important to have a comprehensive understanding of the environmental impacts across the entire life cycle of the industry, including materials, processes and resources; manufacturing and production; lifetime services; reuse; end-of-life; and recycling. One important component of aircraft engines, integral rotors known as Blisks, are made of high-value metallic alloys that require complex and resource-intensive manufacturing processes. The purpose of this paper is to assess the ecological and economical impacts generated through Blisk production and thereby identify significant ‘hot-spots’. Design/methodology/approach - This paper focuses on the methodology and approach for conducting a full-scale Blisk life cycle assessment (LCA) based on ISO 14040/44. Unlike previous papers in the European Aerospace Science Network series, which focused on the first two stages of LCA, this publication delves into the "life cycle impact assessment" and "interpretation" stages, providing an overview of the life cycle inventory modeling, impact category selection and presenting preliminary LCA results for the Blisk manufacturing process chain. Findings - The result shows that the milled titanium Blisk has a lower CO2 footprint than the milled nickel Blisk, which is less than half of the global warming potential (GWP) of the milled nickel Blisk. A main contributor to GWP arises from raw material production. However, no recycling scenarios were included in the analysis, which will be the topic of further investigations. Originality/value - The originality of this work lies in the detailed ecological assessment of the manufacturing for complex engine components and the derivation of hot spots as well as potential improvements in terms of eco-footprint reduction throughout the products cradle-to-gate cycle. The LCA results serve as a basis for future approaches of process chain optimisation, use of "greener" materials and individual process improvements.
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PublicationAn optimization approach for a milling dynamics simulation based on Quantum Computing( 2024-02-01)
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PublicationMachinability study in orthogonal cutting of additively manufactured Inconel 718 with specifically induced porosity( 2024-02-01)In comparison to conventional manufacturing technologies, additive manufacturing (AM) offers great design freedom, the integration of functions into components, new lightweight design concepts and high material efficiency. In aerospace and turbomachinery, this technology is increasingly coming into focus, especially the laser-based powder bed fusion of metals (PBF-LB/M) process. PBF-LB/M is already used for some aerospace components, which are often exposed to high thermal and mechanical loads. Dependent on the component geometry, support structures are required for AM, which then usually have to be removed by machining. One suitable support structure is the use of material with specifically induced porosity. This ensures good heat dissipation and thus homogeneous component properties, high retention forces and short process times in PBF-LB/M. However, the machinability of porous, additively manufactured material has hardly been researched so far. One preliminary investigation of milling porous, additively manufactured Inconel 718, though, showed significantly poorer machinability of the porous material compared to the dense material. To further examine this phenomenon, this paper presents the results of fundamental machinability studies with porous, additively manufactured Inconel 718 in orthogonal cutting. The investigations with tungsten carbide cutting tools on a special fundamental test rig include the analysis of the cutting force, the chip geometry, the chip temperature and the surface quality. The research results provide explanations for the poorer machinability of the porous material and derived approaches for improving the machinability in future studies.
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PublicationBlisk Specific Query Language (BLISQL) - An approach for domain specific data querying in Blisk Manufacturing( 2023-07-18)Product lifecycle management (PLM) is constantly improved by a steadily growing amount of data collected along the product and process development chain. This data supports designing optimized geometries and manufacturing processes. For the optimization of the manufacturing process, data from process design and manufacturing are extracted and processed. The use of a query language is helpful to make the extraction more efficient. Query languages, referring to the specific domain of a component, simplify the formulation of the queries. We present an approach for domain specific data querying in blisk manufacturing based on the Resource Description Framework (RDF) using SPARQL.
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PublicationCloud-based process design in a digital twin framework with integrated and coupled technology models for blisk milling( 2022-12-19)
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PublicationSurface integrity in high-feed roughing of Inconel 718 with SiAlON end mills( 2022)Conventional machining processes for hard-to-machine nickel-based alloys involve carbide tools, which exhibit low productivity at high tool wear rates. Novel tool concepts such as SiAlON-ceramic high-feed end milling tools show great potential to reduce the time required for the roughing process. However, these cutting processes feature high cutting speeds while avoiding cutting fluids, which leads to high thermomechanical loads. Since an unaffected rim zone must be ensured, this paper investigates the surface integrity effects on Inconel 718 machined with SiAlON-ceramic end mills. Particularly, the cutting forces, surface temperature, microhardness and microstructural damages in the cross-section are evaluated. In the selected slot milling operation, surface temperatures of up to 1,250 °C were measured and plastic deformations could be identified up to a depth of 35.5 μm in the bottom of the slot. The side walls are affected up to a depth of 69.6 μm from the surface. Microhardness measurements of the bottom of the slot show a hardening of the machined surface of 17.9 %, which does not reach deeper than 150 μm into the basic structure.
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PublicationTowards Ontology-based Lifecycle Management in Blisk Manufacturing( 2022)
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PublicationPreparation of Papers for IFAC Conferences & Symposia: Adaptive fixture system for reducing machining distortion caused by residual stresses in milling( 2022)Machining distortion caused by residual stresses is one of the major challenges in the production of thin-walled monolithic parts, which are widely used in the aerospace industry. The relevant influencing factors include the selected process parameters, the machining sequence as well as the used fixture system. This paper presents an adaptive fixture system for reducing machining distortion caused by residual stresses in milling. To validate the advantage of this system, machining distortion experiments are conducted on monolithic parts made of Ti-6A1-4V using a conventional and the adaptive fixture system.
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PublicationKnowledge-Based Adaptation of Product and Process Design in Blisk Manufacturing( 2022)Early and efficient harmonization between product design and manufacturing represents one of the most challenging tasks in engineering. Concepts such as simultaneous engineering aim for a product creation process, which addresses both, functional requirements as well as requirements from production. However, existing concepts mostly focus on organizational tasks and heavily rely on the human factor for the exchange of complex information across different domains, organizations, or systems. Nowadays product and process design make use of advanced software tools such as computer-aided design, manufacturing, and engineering systems (CAD/CAM/CAE). Modern systems already provide seamless integration of both worlds in a single digital environment to ensure a continuous workflow. Yet, for the holistic harmonization between product and process design, the following aspects are missing: (i) the digital environment does not provide a complete and data consistent digital twin of the component; this applies especially to the process design and analysis environment, (ii) due to the lack of process and part condition data in the manufacturing environment, an adaptation of product and process design for a balanced functionality and manufacturability is hindered, and (iii) systematic long-term data analytics across different product and process designs with the ultimate goal to transfer knowledge from one product to the next and to accelerate the entire product development process is not considered. This paper presents an exploration concept which couples product design (CAD), process design (CAM), process simulation (CAE), and process adaptation in a single software system. The approach provides insights into correlations and dependencies between input parameters of product/process design and the process output. The insights potentially allow for a knowledge-based adaptation, tackling well-known optimization issues such as parameter choice or operation sequencing. First results are demonstrated using the example of a blade integrated disk (blisk). Early and efficient harmonization between product design and manufacturing represents one of the most challenging tasks in engineering. Concepts such as simultaneous engineering aim for a product creation process, which addresses both, functional requirements as well as requirements from production. However, existing concepts mostly focus on organizational tasks and heavily rely on the human factor for the exchange of complex information across different domains, organizations, or systems. Nowadays product and process design make use of advanced software tools such as computer-aided design, manufacturing, and engineering systems (CAD/CAM/CAE). Modern systems already provide seamless integration of both worlds in a single digital environment to ensure a continuous workflow. Yet, for the holistic harmonization between product and process design, the following aspects are missing: (i) the digital environment does not provide a complete and data consistent digital twin of the component; this applies especially to the process design and analysis environment, (ii) due to the lack of process and part condition data in the manufacturing environment, an adaptation of product and process design for a balanced functionality and manufacturability is hindered, and (iii) systematic long-term data analytics across different product and process designs with the ultimate goal to transfer knowledge from one product to the next and to accelerate the entire product development process is not considered. This paper presents an exploration concept which couples product design (CAD), process design (CAM), process simulation (CAE), and process adaptation in a single software system. The approach provides insights into correlations and dependencies between input parameters of product/process design and the process output. The insights potentially allow for a knowledge-based adaptation, tackling well-known optimization issues such as parameter choice or operation sequencing. First results are demonstrated using the example of a blade integrated disk (blisk).
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PublicationDeep learning and rule-based image processing pipeline for automated metal cutting tool wear detection and measurement( 2022)Tool wear causes costs and quality problems in metal cutting manufacturing processes. This paper contains an approach of digitalization and big data analytical methods to quantify the wear of metal cutting tools. The method developed consists of a pipeline of deep learning operations for processing tool wear images collected with a digital microscope and is complemented by a rule-based approach to measuring wear along the cutting edge of machining tools. The end-to-end approach allows fully automated tool wear detection and measurement that can be used for inline measurements within CNC machine tools for machining applications.
