Felix Geßner

Technical University of Darmstadt

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Eberhard Abele

Technical University of Darmstadt

Christian Bölling

Museum für Naturkunde

Matthias Weigold

Technical University of Darmstadt

Peter F. Pelz

Technical University of Darmstadt

Florian Hoppe

Klinikum Oldenburg

Maximilian Knoll

Krankenhaus der Barmherzigen Brüder Trier

Nicolas Brötz

Technical University of Darmstadt

Peter Groche

Technical University of Darmstadt

Ingo Dietrich

Technical University of Darmstadt

Manuel Rexer

Technical University of Darmstadt

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Technical University of Darmstadt

Institut für Umformtechnik (Germany)

Materials Science & Engineering

Heidelberg University

Darmstadt University of Applied Sciences

Fraunhofer Institute for Manufacturing Engineering and Automation

Saarland University

Technical University of Munich

Fraunhofer Institute for Structural Durability and System Reliability

Fraunhofer Society

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Fortpflanzung von Unsicherheit in Prozessketten*/Propagation of uncertainty in process chains consisting of forming and machining operations

wt Werkstattstechnik online (2018)

Christian Bölling Florian Hoppe Felix Geßner Maximilian Knoll Eberhard Abele

Aufeinanderfolgende Umform- und Zerspanungsprozesse stellen im industriellen Umfeld eine typische Wertschöpfungskette dar. Die Auswirkungen von Unsicherheit werden in solchen Prozessketten bislang nur in Einzelprozessen untersucht. Gegenstand der Untersuchungen im Sonderforschungsbereich 805 ist die Entwicklung einer verketteten, geregelten Prozesskette über die unterschiedlichen Bearbeitungsoperationen hinweg. In einem ersten Schritt wird im Rahmen dieses Aufsatzes die Verkettung eines Taumelprozesses mit einer nachfolgenden Reiboperation in einer Simulation untersucht. Die Geometrie der umgeformten Bauteile wird dazu mittels einer entwickelten Schnittstelle in ein passendes Format umgewandelt. Bei der Simulation der Reibbearbeitung wird der Einfluss der Schneidengeometrie sowie unterschiedlicher Bearbeitungsstrategien auf die Auslenkung des Werkzeuges untersucht.   Successive forming and machining processes represent a common industrial value chain. By now, the effect of uncertainty on these process chains has solely been examined with regard to single processes. The research subject of the Collaborative Research Centre 805 is the development of an interlinked closed-loop controlled process chain consisting of various processing operations. This paper presents the investigation results of an orbital forming process simulation succeeded by a reaming operation. An interface has been designed that converts the geometry of the formed part into a suitable format for the subsequent reaming process simulation. By means of the coupled simulation the influence of cutting edge geometry and machining strategies on tool deflection is examined.

10.37544/1436-4980-2018-01-02-84

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Citations (2)

Fortpflanzung von Unsicherheit in Prozessketten

Christian Bölling Florian Hoppe Felix Geßner Maximilian Knoll Eberhard Abele

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Resilience in Mechanical Engineering - A Concept for Controlling Uncertainty during Design, Production and Usage Phase of Load-Carrying Structures

Applied Mechanics and Materials (2018)

Lena C. Altherr Nicolas Brötz Ingo Dietrich Tristan Gally Felix Geßner

Resilience as a concept has found its way into different disciplines to describe the ability of an individual or system to withstand and adapt to changes in its environment. In this paper, we provide an overview of the concept in different communities and extend it to the area of mechanical engineering. Furthermore, we present metrics to measure resilience in technical systems and illustrate them by applying them to load-carrying structures. By giving application examples from the Collaborative Research Centre (CRC) 805, we show how the concept of resilience can be used to control uncertainty during different stages of product life.

Resilience

10.4028/www.scientific.net/amm.885.187

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Citations (25)

Analysis, Quantification and Evaluation of Uncertainty

Springer tracts in mechanical engineering (2021)

M Schaeffner Eberhard Abele Reiner Anderl Christian Bölling Johannes Brötz

Abstract This chapter describes the various approaches to analyse, quantify and evaluate uncertainty along the phases of the product life cycle. It is based on the previous chapters that introduce a consistent classification of uncertainty and a holistic approach to master the uncertainty of technical systems in mechanical engineering. Here, the following topics are presented: the identification of uncertainty by modelling technical processes, the detection and handling of data-induced conflicts, the analysis, quantification and evaluation of model uncertainty as well as the representation and visualisation of uncertainty. The different approaches are discussed and demonstrated on exemplary technical systems.

Identification

Uncertainty Quantification

Representation

Sensitivity Analysis

10.1007/978-3-030-78354-9_4

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Monitoring & Control - Research Group TEC | Manufacturing Technology

Holger Merschroth Markus Weber Benjamin Brockhaus Patrick Fehn Felix Geßner

10.26083/tuprints-00019809

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Connectivity & Communication - Research Group TEC | Manufacturing Technology

Markus Weber Holger Merschroth Benjamin Brockhaus Alexander Fertig Felix Geßner

10.26083/tuprints-00019807

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Investigation on Tool Deflection During Tapping

Lecture notes in mechanical engineering (2021)

Felix Geßner Matthias Weigold Eberhard Abele

Abstract Tapping is a challenging process at the end of the value chain. Hence, tool failure is associated with rejected components or expensive rework. For modelling the tapping process we choose a mechanistic approach. In the present work, we focus on the tool model, which describes the deflection and inclination of the tool as a result of the radial forces during tapping. Since radial forces always occur during tapping due to the uneven load distribution on the individual teeth, the tool model represents an essential part of the entire closed-loop model. Especially in the entry phase of the tap, when the guidance within the already cut thread is not yet given, radial forces can lead to deflection of the tool. Therefore, the effects of geometric uncertainty in the thread geometry are experimentally investigated, using optical surface measurement to evaluate the position of the thread relative to the pre-drilled bore. Based on the findings, the tool deflection during tapping is mapped using a cylindrical cantilever beam model, which is calibrated using experimental data. The model is then validated and the implementation within an existing model framework is described.

Tapping

10.1007/978-3-030-77256-7_10

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Methods and Technologies for Mastering Uncertainty

Springer tracts in mechanical engineering (2021)

Peter Groche Eberhard Abele Nassr Al-Baradoni Sabine Bartsch Christian Bölling

Abstract Uncertainty affects all phases of the product life cycle of technical systems, from design and production to their usage, even beyond the phase boundaries. Its identification, analysis and representation are discussed in the previous chapter. Based on the gained knowledge, our specific approach on mastering uncertainty can be applied. These approaches follow common strategies that are described in the subsequent chapter, but require individual methods and technologies. In this chapter, first legal and technical aspects for mastering uncertainty are discussed. Then, techniques for product design of technical systems under uncertainty are presented. The propagation of uncertainty is analysed for particular examples of process chains. Finally, semi-active and active technical systems and their relation to uncertainty are discussed.

Identification

Representation

Propagation of uncertainty

10.1007/978-3-030-78354-9_5

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Measuring and modelling of process forces during tapping using single tooth analogy process

Production Engineering (2020)

Felix Geßner Matthias Weigold Eberhard Abele

Abstract For machining internal threads, tapping is a commonly used process. However, due to the complex geometry of the tapping tool, each tooth has a unique geometry resulting in individual forces. Since the forces act synchronously during the process, they partly compensate each other. However, since resulting forces in tapping can cause undesired deflection of the tool which can lead to threads that are not true to gauge or tool breakage, the knowledge of the forces is crucial. To predict the occurring forces on each tooth, different modelling approaches can be used. An approach based on the chip load-cutting force relationship is the mechanistic modelling. Therefore, a suitable force model is of central importance. An empirical force model can be established using an analogy process. Within this work a single tooth analogy process is presented to measure the forces of each tooth separately. By means of a geometrical analysis of the real tool, the chip sizes, such as the cross-section area of the undeformed chip are calculated. Merging the measured process forces from the analogy process and the actual chip sizes, an empirical force model is set up using multivariate regression. The model is validated by implementing it in an existing framework and comparing the results to experimental data.

Tapping

Chip formation

10.1007/s11740-020-01004-4

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Adjustment of Axis Offset Errors during Reaming

Applied Mechanics and Materials (2018)

Andreas Bretz Felix Geßner Tuğrul Öztürk Christian Rinn Eberhard Abele

The reaming process normally takes place at the end of manufacturing processes when a lot of value has already been added. Therefore, reaming plays an important role for the quality of the finished product. To achieve this high quality, the occurring process errors caused by the machine tool and the reamer or incorrect workpiece handling have to be minimised. Measured data of the reaming process allow the prediction of occurring process errors without the need to evaluate the bore with a coordinate measuring machine. However, manufacturing is already completed at this stage and the correction of errors is either no longer possible or very costly. This paper presents an approach to detect axis offsets within the entry phase of the reamer by analysing the process forces. The calculated offset is then compensated by adjusting the nominal value of the motion control.

Reamer

Coordinate-measuring machine

10.4028/www.scientific.net/amm.885.267

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Citations (2)