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Exploiting the technological capabilities of autonomous vehicles as assembly items to improve assembly performance 利用自动驾驶汽车作为装配项目的技术能力,提高装配性能
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2022.100111
Tom Kathmann , Daniel Reh , Julia C. Arlinghaus

The automotive industry is on the brink of transitioning to autonomous vehicles (AVs). This will require highly flexible assembly systems. This paper focuses on exploiting the capabilities of the technology base, e.g., sensors and image recognition, of AVs as assembly items and employing their self-driving function in assembly systems. This fundamentally new approach to matrix manufacturing systems based on autonomously navigating automated guided vehicles (AGVs) and the elimination of set assembly sequences is a growing topic of discussion. This study develops a conceptual framework, based on a systematic literature review and interviews with fifteen experts from three carmakers, for exploring the field of research and assessing the feasibility of employing the technology base of autonomous driving instead of AGVs. This study is intended for assembly planners and researchers of assembly systems in automotive manufacturing.

汽车行业正处于向自动驾驶汽车过渡的边缘。这将需要高度灵活的装配系统。本文的重点是开发AVs作为装配项目的技术基础(如传感器和图像识别)的能力,并将其自动驾驶功能应用于装配系统中。这种基于自主导航自动导引车(AGV)和消除集合装配序列的矩阵制造系统的全新方法是一个越来越多的讨论话题。本研究基于系统的文献综述和对来自三家汽车制造商的十五位专家的采访,开发了一个概念框架,用于探索研究领域,并评估使用自动驾驶技术基础代替AGV的可行性。本研究旨在为汽车制造中的装配规划人员和装配系统研究人员提供帮助。
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引用次数: 0
Multi-criteria and real-time control of continuous battery cell production steps using deep learning 使用深度学习的连续电池生产步骤的多标准和实时控制
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2022.100108
Erik Rohkohl , Malte Schönemann , Yury Bodrov , Christoph Herrmann

Electric vehicles driven by batteries are a key part of a sustainable mobility sector. Unfortunately, battery cell production is still associated with various negative environmental impacts, the use of critical raw materials and high manufacturing costs. The rising battery demand forces automotive original equipment manufacturers to drastically increase their capabilities over the next decades while fulfilling economical and ecological requirements. Continuous production technologies bear the potential to meet future battery cell demands by enabling higher throughputs compared to established batch processes. The control and optimization of continuous battery cell production steps with respect to product quality, manufacturing costs and environmental impacts is challenging due to high parameter spaces as well as temporal dependencies of production processes. Therefore, this study develops a controller that performs real-time optimization by proposing set parameters leading to desired quality, minimal costs and impacts of manufacturing activity. The controller is implemented using a deep learning model incorporating sequential information of the production process. A continuous mixing process with data acquired from a battery cell pilot line is used to validate the outlined controller. As result, the implementation for this use case achieves a relative error of 7.63% across all controllable parameters.

电池驱动的电动汽车是可持续移动领域的关键组成部分。不幸的是,电池生产仍然与各种负面的环境影响、关键原材料的使用和高制造成本有关。不断增长的电池需求迫使汽车原始设备制造商在未来几十年大幅提高其能力,同时满足经济和生态要求。与现有的批量生产工艺相比,连续生产技术具有更高的吞吐量,从而具有满足未来电池需求的潜力。由于生产过程的高参数空间和时间依赖性,在产品质量、制造成本和环境影响方面对连续电池生产步骤的控制和优化具有挑战性。因此,本研究开发了一种控制器,通过提出一组参数来实现实时优化,从而实现所需的质量、最小的成本和制造活动的影响。控制器采用深度学习模型,结合生产过程的顺序信息实现。连续混合过程与从电池中试线获得的数据被用来验证概述的控制器。因此,该用例的实现在所有可控参数上实现了7.63%的相对误差。
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引用次数: 0
Introducing a general-purpose augmented reality platform for the use in engineering education 介绍一种用于工程教育的通用增强现实平台
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2023.100116
Joshua Grodotzki, Benedikt Tobias Müller, A. Erman Tekkaya

There is a lack of a universal Augmented Reality platform which can be used in manufacturing engineering and other education fields to display models, processes, animations and simulations alike. Such a platform has been developed as part of this contribution and enables instructors to manage online courses, teaching units and even entire study programs. To enhance the teaching in the classroom by using Augmented Reality visualizations, a new application has been developed, which runs on iOS as well as Android systems and displays the various objects along with additional information uploaded by the instructors. A novel storage format was devised which reduces the storage size of various models significantly wherefore performance on the phone's end is improved. Various common 3D file formats, such as STL, OFF and OBJ, can be imported and automatically converted to this new format. The same applies for results from FEM software Abaqus, MoldFlow and HyperXtrude. Results formatted to be analyzed by the popular pre-/post-processor GiD can also be uploaded at no additional expense. The users of the smartphone app can view, inspect and interact with the models and animations. The platform and app are designed for an easy-to-use setup by the educators and an intuitive use by the students.

目前还缺乏一个通用的增强现实平台,可以用于制造工程和其他教育领域,以显示模型、过程、动画和模拟。这样一个平台已经被开发出来,作为这一贡献的一部分,它使教师能够管理在线课程、教学单元甚至整个学习计划。为了通过使用增强现实可视化来增强课堂教学,我们开发了一个新的应用程序,它可以在iOS和Android系统上运行,并显示各种物体以及教师上传的附加信息。设计了一种新的存储格式,大大减少了各种型号的存储大小,从而提高了手机端的性能。可以导入各种常见的3D文件格式,如STL、OFF和OBJ,并自动转换为这种新格式。同样适用于有限元软件Abaqus, MoldFlow和HyperXtrude的结果。通过流行的前/后处理器GiD格式化以供分析的结果也可以上传,而无需额外费用。智能手机应用程序的用户可以查看、检查模型和动画,并与之互动。该平台和应用程序旨在为教育工作者提供易于使用的设置和学生的直观使用。
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引用次数: 3
Investigations on the thermal conditions during laser beam welding of high-strength steel 100Cr6 100Cr6高强度钢激光焊接热条件的研究
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2023.100118
Eric Wasilewski, Nikolay Doynov, Ralf Ossenbrink, Vesselin Michailov

This study examines the thermal conditions during laser beam welding of 100Cr6 high-strength steel using a TruDisk5000 disc laser with a continuous adjustable power range of 100–5000 W. Two parameter sets, characterized by laser power and welding speeds, were analyzed by thermal-metallurgical FE simulations to determine their impact on the thermal conditions during welding. The results show a significant shift in heat coupling, with conduction transitioning to deep penetration welding. As a result of the high welding speeds and reduced energy input, extremely high heating rates up to 2∙104 K s−1 (set A) respectively 4∙105 K s−1 (set B) occur. Both welds thus concern a range of temperature state values for which conventional Time-Temperature-Austenitization (TTA) diagrams are currently not defined, requiring calibration of the material models through general assumptions. Also, the change in energy input and welding speed causes significantly steep temperature gradients with a slope of approximately 5∙103 K mm−1 and strong drops in the temperature rates, particularly in the heat affected zone. The temperature cycles also show very different cooling rates for the respective parameter sets, although in both cases they are well below a cooling time t8/5 of 1 s, so that the phase transformation always leads to the formation of martensite. Since the investigated parameters are known to cause a loss of technological strength and conditionally result in cold cracks, these results will be used for further detailed experimental and numerical investigation of microstructure, hydrogen distribution, and stress-strain development at different restraint conditions.

本研究使用功率范围为100 - 5000w的连续可调TruDisk5000圆盘激光器,研究了100Cr6高强度钢的激光束焊接过程中的热条件。通过热冶金有限元模拟,分析了激光功率和焊接速度两组参数对焊接过程热条件的影响。结果表明,热耦合发生了明显的转变,由传导过渡到深熔接。由于焊接速度快,能量输入少,加热速率极高,分别达到2∙104 K s−1 (a组)和4∙105 K s−1 (B组)。因此,这两个焊接都涉及到一系列温度状态值,而传统的时间-温度-奥氏体化(TTA)图目前还没有定义,需要通过一般假设来校准材料模型。此外,能量输入和焊接速度的变化导致温度梯度急剧下降,斜率约为5∙103 K mm−1,温度速率急剧下降,特别是在热影响区。在不同的参数下,温度循环也显示出不同的冷却速率,尽管在这两种情况下,它们都远低于冷却时间8/5 (1 s),因此相变总是导致马氏体的形成。由于已知所研究的参数会导致技术强度损失并有条件地导致冷裂纹,因此这些结果将用于进一步详细的微观结构、氢分布和不同约束条件下应力-应变发展的实验和数值研究。
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引用次数: 0
Creation of self-hardening aluminum phosphate binders for manufacturing foundry cores 铸造型芯用自硬化磷酸铝粘结剂的研制
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2023.100114
I. Petryk , R. Liutyi , А. Kocheshkov , A. Myslyvchenko , D. Liuta

The aims of this publication is to study the physical and chemical conditions of formation of self-hardening aluminum phosphate binders based on orthophosphoric acid and fine-grained aluminum powder, research of its chemical structure and properties of core mixtures for foundry production.

The methods used in the work are: X-ray phase analysis on the Rigaku Ultima IV, differential thermogravimetric analysis on the STA 449 C. Orthophosphoric acid 85% concentration and finely dispersed aluminum powder were used as materials. Samples of core mixtures were made on the basis of quartz sand with an average particle size of 0.2 … 0.3 mm.

As a result of the experiments, it was established that in the system of orthophosphoric acid and finely dispersed aluminum powder, a chemical interaction occurs at ambient temperature, which leads to the formation of a phosphate binder. It has been confirmed that it is aluminum orthophosphate in the form of berlinite, and it does not undergo phase transformations, namely it is thermally stable when heated from 20 to 1000 оС. A significant advantage for core mixtures in foundry production is that the chemical interaction in this system does not begin immediately after mixing the components, but after 5 … 10 min, which is explained by the presence of protective oxide or hydroxide films on the aluminum particles. This ensures the period of technological suitability of the core mixture, and subsequently ensures its self-hardening.

In contrast to previously known aluminum phosphate binders, which required heating from 200 to 300 оС for their hardening, a self-hardening aluminum phosphate binders and the core mixture based on it were created for the first time.

With the amount of 2 … 3% of orthophosphoric acid and 1 … 2% of aluminum powder, after 1 h the strength indicators of the mixture based on quartz sand exceed 1 MPa, which is sufficient for the production of foundry cores.

本论文的目的是研究基于正磷酸和细粒铝粉的自硬化磷酸铝粘结剂形成的物理和化学条件,研究其化学结构和铸造用芯料混合物的性能。采用的方法为:以浓度为85%的正磷酸和细分散的铝粉为材料,对Rigaku Ultima IV进行x射线相分析,对STA 449 c进行差示热重分析。以平均粒径为0.2 ~ 0.3 mm的石英砂为原料,制备了岩心混合物样品。实验结果表明,正磷酸与分散的铝粉在室温下发生化学相互作用,形成了磷酸盐粘结剂。经证实,它是白铝石形式的正磷酸铝,不发生相变,即从20℃加热到1000℃时热稳定оС。在铸造生产中,核心混合物的一个显著优势是,该系统中的化学相互作用不是在混合组分后立即开始,而是在5…10分钟后开始,这可以解释为铝颗粒上存在保护性氧化物或氢氧化物膜。这确保了芯材混合物的技术适用性,并随后确保了其自硬化。先前已知的磷酸铝粘结剂需要加热到200到300 оС才能硬化,与之相反,我们首次制造了一种自硬化磷酸铝粘结剂和基于它的核心混合物。当正磷酸添加量为2.3%,铝粉添加量为1.2%时,1 h后石英砂混合料的强度指标均超过1 MPa,足以用于铸造芯材的生产。
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引用次数: 0
Impact of additive manufacturing on titanium supply chain: Case of titanium alloys in automotive and aerospace industries 增材制造对钛供应链的影响:以汽车和航空航天行业的钛合金为例
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2023.100112
Patricia Nyamekye , Saeed Rahimpour Golroudbary , Heidi Piili , Pasi Luukka , Andrzej Kraslawski

Additive manufacturing (AM) is a promising technology for designing complex metallic pieces for different sectors with resource and time effectiveness. Titanium (Ti) is an essential critical material for AM development. AM can produce intricate and cost-effective components with Ti alloys for the transportation sector which would not be possible with conventional manufacturing (CM) technologies. This study assesses the impact of AM on the life cycle of Ti and its alloys by using review (numerical data, case examples) and dynamics simulation modelling. This article quantifies potential environmental benefits and examines aspects related to using Ti alloys in the automotive and aerospace industries. Mass flow, energy consumption and related greenhouse gas (GHG) emissions are assessed by making a comparison between subcategories of AM including binder jetting (BJT), directed energy deposition (DED), electron beam-based powder bed fusion (EB-PBF), and laser-based powder bed fusion (L-PBF) and CM processes including forging, milling, machining, and die casting. The results show that the AM subcategories considered potentially reduce manufacturing phase energy consumption and GHG emissions except for L-PBF. The findings highlight that an inclusive consideration of all life cycle phases is needed to fully identify potential benefits of AM for industries. Also, the scenario analysis in this study proposes the opportunity for saving mass and minimizing energy consumption and GHG emissions by optimizing the structural design and manufacturing processes for Ti components.

增材制造(AM)是一种很有前途的技术,可以为不同行业设计具有资源和时间效益的复杂金属件。钛(Ti)是AM开发的重要关键材料。AM可以用Ti合金为运输部门生产复杂且具有成本效益的部件,这在传统制造(CM)技术中是不可能的。本研究通过回顾(数值数据、实例)和动力学模拟建模,评估了AM对Ti及其合金生命周期的影响。本文量化了潜在的环境效益,并探讨了在汽车和航空航天工业中使用钛合金的相关方面。通过比较AM的子类别,包括粘结剂喷射(BJT)、定向能沉积(DED)、电子束基粉末床聚变(EB-PBF)、激光基粉末床融合(L-PBF)和CM工艺,包括锻造、铣削、机加工和压铸,来评估质量流、能源消耗和相关温室气体(GHG)排放。结果表明,除L-PBF外,所考虑的AM子类别可能会降低制造阶段的能源消耗和GHG排放。研究结果强调,需要对所有生命周期阶段进行包容性考虑,以充分确定AM对行业的潜在好处。此外,本研究中的情景分析提出了通过优化钛部件的结构设计和制造工艺来节省质量、最大限度地减少能源消耗和温室气体排放的机会。
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引用次数: 7
Experimental investigation on surface topography in submerged abrasive waterjet cutting of Ti6Al4V 浸没磨料水射流切割Ti6Al4V表面形貌的实验研究
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2023.100113
Paramjit Mahesh Thakur, Dadarao Niwrutti Raut

Some of the key issues with AWJ technology are high roughness, low depth of smooth zone, and grit embedment. When compared to the unsubmerged AWJ, the submerged AWJ gives less divergence and produces higher energy at the cross section of the jet. Hence, this study examined the effects of pressure, traverse rate, and standoff distance on roughness, depth of smooth zone, and grit embedment in both AWJ conditions. Here, single factor experiments are conducted for experimental investigation wherein one factor is varied and the others are kept constant. In comparison, the submerged AWJ gave significant improvement in the roughness and depth of the smooth zone at lower levels of pressure (150 and 200 MPa), higher levels of traverse rate (300 and 350 mm/min) and standoff distance (4, 5 and 6 mm). The significant difference in grit embedment was observed at lower levels of traverse rate (150 and 200 mm/min), higher levels of pressure (300 and 350 MPa), and all the levels of standoff distance (2, 3, 4, 5, and 6 mm). The grit embedment in the submerged condition was lower due to the removal of initially embedded grits due to flushing action produced by cavitation initiation.

磨料射流技术的一些关键问题是高粗糙度、低光滑区深度和砂粒嵌入。与未浸入式水射流相比,浸入式水射流发散更小,在射流截面处产生更高的能量。因此,本研究考察了两种AWJ条件下压力、穿越速率和距离对粗糙度、光滑区深度和砂粒嵌入的影响。这里采用单因素实验进行实验调查,其中一个因素变化,其他因素保持不变。相比之下,在较低压力(150和200 MPa)、较高穿越速度(300和350 mm/min)和距离(4、5和6 mm)下,浸没式AWJ在光滑区的粗糙度和深度方面都有显著改善。在较低的穿越速度(150和200 mm/min)、较高的压力(300和350 MPa)以及所有水平的距离(2、3、4、5和6 mm)下,砂粒嵌入的显著差异都被观察到。在水下条件下,由于空化引发的冲刷作用使最初嵌入的砂粒被去除,因此砂粒的嵌入量较低。
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引用次数: 1
Modelling of wire-arc additive manufacturing – A review 电弧增材制造建模——综述
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2023.100121
R.F.V. Sampaio , J.P.M. Pragana , I.M.F. Bragança , C.M.A. Silva , C.V. Nielsen , P.A.F. Martins

This paper is focused on wire-arc additive manufacturing and has a twofold objective. First, to deliver an overall state-of-the-art review of the different aspects of modelling. Second, to provide a detailed analysis of the macro-scale finite element modelling. The methodology draws from the fundamentals of the macro, meso and micro-scale modelling of the process, to the main strategies and objectives behind the development of analytical, statistical, machine learning and finite element analyses of macro-scale modelling. The intention is to provide information on the pre-processing requirements, solution techniques and results that are currently being worked on by some of the leading researchers in the field. This will enable readers to understand the main challenges, relevance, and assumptions of the different published works. The theoretical and numerical aspects are intentionally kept in a clear and understandable level so that users of finite element computer programs having the know-how on wire-arc additive manufacturing can bridge the actual gap to the developers of the programs.

本文的重点是线弧增材制造,有两个目标。首先,对建模的不同方面进行全面的最新研究。其次,提供宏观尺度有限元建模的详细分析。该方法从过程的宏观,中观和微观尺度建模的基本原理,到宏观尺度建模的分析,统计,机器学习和有限元分析发展背后的主要策略和目标。其目的是提供有关该领域一些主要研究人员目前正在研究的预处理要求、解决方案技术和结果的信息。这将使读者能够理解不同出版作品的主要挑战、相关性和假设。理论和数值方面有意保持在一个清晰易懂的水平,以便具有线弧增材制造专业知识的有限元计算机程序的用户可以弥合程序开发人员的实际差距。
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引用次数: 2
Numerical and experimental analysis of margin geometries of twist drills in deep hole machining operations 麻花钻深孔加工边缘几何形状的数值与实验分析
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2023.100120
Christopher Krebs , Dennis Heyser , Bernhard Schweizer , Marcel Volz , Eberhard Abele , Matthias Weigold

In deep hole machining operations with twist drills, whirling vibrations lead to a significant increase in hole diameter deviation and circularity error. In this article, a nonlinear physical model with special consideration of the contact area between the margins of the tool and the workpiece is developed to predict the hole circularity of drilling operations. Numerical simulations are used to study the geometry of the drilling tool to propose a new margin design. In an experimental study, it is shown that the newly developed margin geometry for twist drill tools decreases radial vibrations and leads to a significant improvement in hole diameter deviations and hole circularities.

在麻花钻深孔加工中,旋转振动会导致孔径偏差和圆度误差显著增大。本文建立了一个非线性物理模型,特别考虑了刀具边缘与工件之间的接触面积,以预测钻孔作业的孔圆度。通过数值模拟研究了钻具的几何形状,提出了一种新的余量设计方法。一项实验研究表明,新开发的麻花钻工具边缘几何结构可以减少径向振动,并显著改善孔径偏差和孔圆度。
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引用次数: 0
Melting modes of laser powder bed fusion (L-PBF) processed IN718 alloy: Prediction and experimental analysis 激光粉末床熔化(L-PBF)处理IN718合金的熔化模式预测与实验分析
Q2 ENGINEERING, INDUSTRIAL Pub Date : 2023-05-01 DOI: 10.1016/j.aime.2022.100106
S. Pramod, D. Kesavan

The present study explores a combination of numerical and simulation approaches to generate a process map for identifying the regimes of conduction and keyhole modes of melting and verify the same with experimental data. Finite Element based simulation studies were conducted to determine the regions of conduction mode, keyhole mode, and transition by varying the laser power and speed. Single tracks and density cubes were processed based on the simulation results to confirm the melting modes and study its effect on microstructure and hardness. Increase in volumetric energy density (VED) causes a shift in microstructure of single tracks, from a mix of short columnar and equiaxed grains in conduction mode to long columnar grains in keyhole mode, with an overall increase in the grain size. The melt pool depth to width ratio also increases with VED. The VED based criteria alone cannot determine melting modes as the single-track samples at 81 J/mm3 exhibited both conduction mode (at 250 W) and keyhole mode (at 350 W). Almost all the printed cubes showed high density (>99.9%) irrespective of melting mode. Similar to single track the average grain size of bulk samples increased with increase in VED. The bulk samples were subjected to three different heat treatments (Homogenisation, Solution treatment and Direct Double Aging) to study their effect on the microstructures and mechanical properties. Homogenisation resulted in near identical equiaxed microstructure irrespective of processing parameters. The highest hardness of about 470 HV was observed for the direct double aged samples.

本研究探索了数值和模拟方法的结合,以生成一个过程图,用于识别熔化的传导和锁孔模式,并用实验数据验证相同的过程图。通过改变激光功率和速度,进行了基于有限元的模拟研究,确定了传导模式、锁孔模式和过渡模式的区域。在模拟结果的基础上加工了单轨和密度立方体,确定了熔化方式,并研究了其对显微组织和硬度的影响。体积能量密度(VED)的增加导致单轨微观结构发生转变,从导通模式下的短柱状和等轴晶粒混合到锁孔模式下的长柱状晶粒,晶粒尺寸总体增大。熔池深宽比也随温度升高而增大。单轨道样品在81 J/mm3下同时表现为传导模式(250 W)和锁孔模式(350 W)。几乎所有的打印立方体都显示出高密度(>99.9%),而不考虑熔化模式。与单径迹相似,散装样品的平均晶粒尺寸随VED的增加而增加。采用三种热处理方法(均质化、固溶和直接双时效)研究其对合金组织和力学性能的影响。无论加工参数如何,均质化都导致了几乎相同的等轴微观结构。直接双时效试样的最高硬度约为470 HV。
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引用次数: 2
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Advances in Industrial and Manufacturing Engineering
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