Advanced Materials Research Vol. 1018

Abstract: In this presentation at first the overall economic importance of gear manufacturing is highlighted. Main application areas of gear boxes are analysed with regard to their future orientation, namely the automotive industry, the wind energy sector, aircraft applications as well as machine tools. Still by far the most important and dominating technology for gear manufacturing is gear hobbing. This process is briefly explained and main characteristics are mentioned. Besides the industrial aspects there is also a strong attention for a better understanding of the fundamental aspects of gear hobbing.

Abstract: Industrial robots are usually not suitable for high-precision applications due to their limited absolute accuracy. This issue can be solved by calibrating the robot using an adequate model of its kinematic chain and physical behaviour. However, this presupposes a deep understanding of the effects that influence the absolute accuracy and repeatability of the robot. This paper outlines a set of experiments to gain this knowledge by analysing the effects that limit the precision and furthermore presents a way for the proper visualisation of the consequent errors. The investigation includes a range of robots with different characteristics to gather valid and preferably universal information for off-the-shelf industrial robots.

Abstract: In the context of casting mould inspection, the conventional paper-based provision of information for workers can be characterised by a conflict of objectives. On the one hand, a minimisation of the cognitive load of the worker is desirable. To this end the inspection procedure is oriented on the complete processing of each view of the single-part drawing. This leads to a necessary change between inspection devices within individual views. On the other hand, a resource-efficient use of inspection equipment is desirable. To this end, the inspection tasks are grouped so that for each group one single inspection device is assigned. This requires a change between the views of the single-part drawing within each inspection device, which increases worker’s cognitive load. By means of a realistic representation of the inspection operations to be carried out, by using a Worker Information System which is based on animated graphical representations (dynamic visualisation), the increase of the cognitive load that is caused by the resource-efficient use of inspection equipment could be compensated.

Abstract: Ultrasonic non-contact handling is used to manipulate surface sensitive and fragile workpieces, e.g. wafers and glass plates, without mechanical contact. While the technology is available forapplications at room temperature, some of the manufacturing processes of products mentioned aboverequire handling at elevated temperatures. To enable this technology for handling in thermal processesan ultrasonic system for increased working temperatures is required. In order to adapt the ultrasonicsystem to the limited working temperature of the actuator, the handling system has to be operated attwo different temperatures. Due to the small change of the Young's modulus over temperature, quartzglass was chosen as material for the components in the high temperature region. The paper presentsthe design and manufacturing of a novel ultrasonic system operated at 790 °C while the actuator iskept at room temperature.

Abstract: In this paper, we present a robot programming system taking into account natural communication and process integrated simulation as well as a unified robot control layer and an interface towards the Digital Factory for program transmission. We choose an integrative approach including markerless gesture recognition and a mobile Augmented Reality simulation on common handheld devices, e.g. smartphones or tablet-PCs. The user is enabled to draw poses and trajectories into the workspace of the robot supported with simultaneous visual feedback in Augmented Reality. In addition the user can adapt the robot program by gestural manipulation of poses and trajectories. Within a task-oriented implementation of the robot program a pick and place task was implemented through the programming by demonstration principle. With the help of a user study we evaluate programming duration, programming errors and subjective assessment compared with Teach-In and Offline Programming. The analysis of the results shows a significant reduction of programming duration as well as a reduction of programming errors compared with Teach-In. Furthermore, most participants favour the spatial programming system.

Abstract: Slowly but steadily, more and more electrical vehicles push onto the consumer market. To produce electrical engines cost efficient, in first-class quality and in sufficient quantity, it is indispensable to understand the process of winding. The prediction of the wire behaviour is one of the key challenges of coil winding. Therefore, a detailed model is built to investigate the wire behaviour during the linear winding process. The finite element based simulation tool ANSYS Workbench® serves as the static structural component tool. To represent the high dynamic process of winding within this simulation, some first adaptions have to be made. This means, that dynamic influences such as rotational speed or acceleration of the coil body are neglected. Within the static structural analysis, the given boundary conditions are applied to the model. The material properties of the wire under scrutiny are validated by a tensile test and by the values of the datasheets. In order to achieve the best convergence, different contact algorithms are selected for each individual contact behaviour. Furthermore, specific adjustments to the mesh are necessary to gain significant results. State of the art in coil winding is an experimental procedure, which delivers good process parameters and, thus, expertise in winding technology. However, there are a lot of different, interacting parameters, which have to be optimized in terms of boundary conditions. The simulation model of the winding process, where varying parameters can be optimized pertaining to the optimal winding result, calls for extensive research in the field. The generated model enables the user not only to influence the process parameters but also to modify the geometry of the winding body. To make the simulation scientifically sound, it is validated by experiments.

Abstract: Circular saw blades are very widespread in wood machining. They are used in different batches and sizes and in large quantities from hand tools to large machining centers. Because of this huge range of applications the circular saws have gained great importance in the industry. The rising request to improve the cutting quality, reduce the noise emission and increase the life time requires improvement measures for the dynamic behavior of the circular saw blade. The roll tensioning of the circular saw blade has been empirically established as an elegant solution to improve the static and dynamic properties of the circular saw blade. However, there are several influencing parameters for this process that have not yet been studied scientifically accurate. A scientific and economical solution for the study of various roll tensioning parameters is a simulation model based on finite elements method (FEM) that analyzes the effects on the dynamic behavior of circular saw blade. In this work, a simulation model for roll tensioning of circular saw blades is presented. With this simulation model, the residual stresses induced by the roll tensioning can be calculated. This is very relevant for the changing of dynamic properties of the circular saw blade, such as the shifting of eigenvalues and reduction of side run out. Furthermore, this simulation model allows the investigation of various roll tensioning parameters. This investigation helps to gain a better understanding of the relationship between roll tensioning and improvement of dynamic behavior of circular saw blades. Furthermore, it helps to find the optimization potential of the roll tensioning process which is one of the most important parts of the production line of circular saw blades.

Abstract: The processing of fiber reinforced plastics is one of the main research areas at the Institute for Machine Tool and Factory Management of the Technical University of Berlin. In this process new tool concepts and innovative process strategies are developed, tested and prepared for the industrial application. This report presents the latest research results in the field of High-Speed-Cutting of fiber-reinforced plastics.

Abstract: A variety of current scientific work shows the importance and possibilities of an effective conditioning of tribological contacts to minimize friction and wear, respectively an increase in performance of tribological highly stressed components. By slight modifications of the finishing process positive effects like the increase of lifetime or increase of power can therefore be generated. Based on this approach the tribological system piston ring/cylinder running surface of internal combustion engines is an example with high potential for optimization of production. This paper introduces alternative production and conditioning processes. The evaluation of chemical modifications of boundary layers, which are used in addition to the topography as a representative indicator for the description of the functionalities of produced surfaces is considered to be a special aspect. The present paper combines considerations of manufacturing technology with tribological tests showing the relationships and dependencies between the process characteristics of finishing and the operational behavior of the examined components.