M.Sc.

Ganser, Philipp

Filters

1
Reset filters

Settings
Now showing 1 - 10 of 36
No Thumbnail Available
Publication

Life cycle analysis results for engine blisk LCA

2024-02-05 , Fricke, Kilian , Bergs, Thomas , Ganser, Philipp , Seimann, Martin

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.

View
No Thumbnail Available
Publication

Blisk Specific Query Language (BLISQL) - An approach for domain specific data querying in Blisk Manufacturing

2023-07-18 , Schiller, Sven , Landwehr, Markus , Vinogradov, Georg , Ganser, Philipp , Bergs, Thomas

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.

View
No Thumbnail Available
Publication

Resilienz in der Luftfahrt

2022-09-16 , Gierlings, Sascha , Heinen, Daniel , Bergs, Thomas , Horstkotte, Rainer , Ganser, Philipp

Pandemie, Nachhaltigkeits- und Effizienzziele stellt fortlaufende Herausforderungen an die Luftfahrtindustrie: Sie muss Antriebstechnologien weiterentwickeln sowie neue Werkstoffe und Fertigungsverfahren erschließen. Domänenübergreifende digitale Zwillinge bergen bisher ungenutzte Potenziale, um wachsende Anforderungen mithilfe von Digitalisierung zu bewältigen, wie ein praxisnahes Beispiel aus der Fertigung von Luftfahrtkomponenten im Whitepaper aufzeigt. Das Trendthema Nachhaltigkeit treibt Innovationen an und ergänzt Produktivität, Qualität und Kosten als Kriterium für strategische Unternehmensentscheidungen. Das Bewusstsein dafür muss sich beim Personal festigen sowie die Fähigkeit, resiliente Prozesse zu bewältigen. Solche Prozesse stellen den erfolgreichen Umgang mit Störungen sicher. So kann sich eine Störung sogar zu einer Chance wandeln. Das Fraunhofer IPT bündelt im Whitepaper sein Expertenwissen, wie sich die Dimensionen »Technologie«, »Digitalisierung«, »Nachhaltigkeit« und »Personal« im Kontext der Luftfahrt verbinden lassen, um diese Chance zu ergreifen.

View
No Thumbnail Available
Publication

Preparation of Papers for IFAC Conferences & Symposia: Adaptive fixture system for reducing machining distortion caused by residual stresses in milling

2022 , Landwehr, Markus , Kalocsay, Roman , Kolvenbach, Christian , Ganser, Philipp , Bergs, Thomas

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.

View
No Thumbnail Available
Publication

An optimization approach for a milling dynamics simulation based on Quantum Computing

2024-02-01 , Schröder, Stefan , Danz, Sven , Kienast, Pascal , König, Valentina , Ganser, Philipp , Bergs, Thomas

Since the machining of complex aerospace components, like integral compressor-rotors (blade integrated disks), is very cost-intensive, optimizing the process by means of process simulations is an active field of research. With the rise of Quantum Computing, a new instrument with high optimization potential is moving into focus. In this paper, a possible application of Quantum Computing for the machining simulation of multi-axis milling of thin-walled aerospace components is discussed. For this reason, a simulation framework used for the milling simulation is analyzed and each component is evaluated separately in relation to Quantum Computing. Parts of the Harrow, Hassidim, and Lloyd algorithm are proposed to enhance the Finite-Element simulation-based component, like the modal analysis for dynamics simulation. This algorithm can solve linear system problems with exponential speed-up over the classical method. The paper presents a roadmap on how the classical steps of a modal analysis for dynamics simulation could be replaced by quantum algorithms based on quantum phase estimation. The implementation of the first working steps is presented to validate this approach. The linear system problem, arising from the dynamics simulation, is analyzed in detail and a minimal value problem of linear coupled oscillators is derived.

View
No Thumbnail Available
Publication

Cloud-based process design in a digital twin framework with integrated and coupled technology models for blisk milling

2022-12-19 , Rudel, Viktor , Kienast, Pascal , Vinogradov, Georg , Ganser, Philipp , Bergs, Thomas

In this publication, the application of an implemented Digital Twin (DT) framework is presented by orchestration of CAM-integrated and containerized technology models carrying out FEM-coupled simulations for the finishing process of a simplified blade integrated disk (blisk) demonstrator. As a case study, the continuous acquisition, processing and usage of virtual process planning and simulation data as well as real machine and sensor data along the value chain is presented. The use case demonstrates the successful application of the underlying DT framework implementation for the prediction of the continuously changing dynamic behavior of the workpiece and according stable spindle speeds in the process planning phase as well as their validation in the actual manufacturing phase.

View
No Thumbnail Available
Patent

Verfahren zur Erzeugung einer virtuellen Geometrie und System zur Datenverarbeitung

2022-09-15 , Venek, Tommy , Gerretz, Vincent , Ganser, Philipp , Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V.

Die Erfindung betrifft ein Verfahren, insbesondere ein computerimplementiertes Verfahren, zur Erzeugung einer virtuellen Geometrie (32), ein Verfahren zur Erzeugung eines digitalen Zwillings, sowie ein System zur Datenverarbeitung und ein Computerprogramm. Insbesondere betrifft die Erfindung ein Verfahren, insbesondere computerimplementiertes Verfahren, zur Erzeugung einer virtuellen Geometrie eines mit einer Bearbeitungsmaschine (2) hergestellten und/oder herzustellenden Bauteils (8) mit einer Sollgeometrie, umfassend die Schritte: Erfassen von Maschineninformationen (12, 14), die mindestens einen eine Geometrie des Bauteils (8) beeinflussenden Maschinenparameter der Bearbeitungsmaschine (2) charakterisieren, Ermitteln (230, 240, 250) mindestens eines Bauteilfaktors (30) basierend auf den Maschineninformationen (12, 14) und der Sollgeometrie (10), und Erzeugen (260) einer ersten virtuellen Geometrie (32) als digitales geometrisches Abbild des hergestellten und/oder herzustellenden Bauteils (8) basierend auf dem Bauteilfaktor (30).

View
No Thumbnail Available
Publication

Machinability study in orthogonal cutting of additively manufactured Inconel 718 with specifically induced porosity

2024-02-01 , Schneider, Sebastian A.M. , Li, Yupeng , Boseila, Jonas , Ganser, Philipp , Bergs, Thomas , Schleifenbaum, Johannes Henrich

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.

View
No Thumbnail Available
Publication

Resilience in Aviation

2022-11-14 , Gierlings, Sascha , Heinen, Daniel , Bergs, Thomas , Horstkotte, Rainer , Ganser, Philipp

Pandemic, sustainability and efficiency targets pose ongoing challenges for the aviation industry: It must continue to develop propulsion concepts and tap into new materials and manufacturing processes. Cross-domain digital twins harbor previously untapped potential for mastering growing requirements with the help of digitization, as a practical example from the production of aerospace components shows in the white paper. The trend topic of sustainability drives innovation and complements productivity, quality and costs as criteria for strategic corporate decisions. Awareness of this must be consolidated among personnel, as well as the ability to manage resilient processes. Such processes ensure the successful handling of disruptions. In this way, a disruption can even turn into an opportunity. In the white paper, the Fraunhofer IPT pools its expert knowledge on how the dimensions of "technology", "digitalization", "sustainability" and "employees" can be combined in the context of aviation in order to seize this opportunity.

View
No Thumbnail Available
Publication

Surface integrity in high-feed roughing of Inconel 718 with SiAlON end mills

2022 , Zimmermann, Richard , Michel-Angeli, Niklas , Welling, David , Ganser, Philipp , Bergs, Thomas

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.

View