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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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PublicationInitial experiments to regenerate the surface of plasma-facing components by wire-based laser metal deposition( 2024)
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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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PublicationOn the importance of domain expertise in feature engineering for predictive product quality in production( 2023-07-18)Machine Learning (ML) offers significant potential for quality management in production with predictive analytics. Key aspects to building ML models are the selection and engineering of features from data. They allow the usage of relevant data for training ML models. Using the right features consequently improves the quality of the ML models. However, feature engineering requires knowledge of the data, data preprocessing techniques, algorithms, the domain, and use case. Hence, automatic feature engineering tools have become popular. In this paper, we investigate how domain experts and automatic tools compare for engineering features based on a time series dataset from production.
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PublicationAdditiv gefertigte Gewindewerkzeuge aus HSS( 2023-07-17)Eine verlängerte Werkzeuglebensdauer bei der Gewindefertigung ist durch eine Neugestaltung der inneren Kühlschmierstoffzufuhr am Werkzeug möglich. Der Einsatz additiver Fertigungsverfahren wie dem Laser Powder Bed Fusion erlaubt die Fertigung innen liegender und komplexer Kanal- und Düsengeometrien. In umfangreichen Einsatztests konnten Prozesssicherheit und Potenziale additiv gefertigter Gewindeform- und Gewindeschneidwerkzeuge aus Schnellarbeitsstahl nachgewiesen werden.
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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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PublicationAdditively Manufactured Robot Gripper Blades for Automated Cell Production Processes( 2022-10-14)The automation of cell production processes demands strict requirements with regard to sterility, reliability, and flexibility. Robots work in such environments as transporting devices for a huge variety of disposables, e.g., cell plates, tubes, cassettes, and other objects. Therefore, the blades of their grippers must be designed to hold all of these different materials in a stable, gentle manner, and in defined positions, which means that the blades require complex geometries. Furthermore, they should have as few edges as possible, so as to be easy to clean. In this report, we demonstrate how these requirements can be met by producing stainless steel robot grippers by additive manufacturing.
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PublicationSimulation of the Refractive Index Variation and Validation of the Form Deviation in Precisely Molded Chalcogenide Glass Lenses (IRG 26) Considering the Stress and Structure Relaxation( 2022-09-29)
