@article{AbbasBalcBremenetal.2022, author = {Abbas, Karim and Balc, Nicolae and Bremen, Sebastian and Skupin, Marco}, title = {Crystallization and aging behavior of polyetheretherketone PEEK within rapid tooling and rubber molding}, series = {Journal of Manufacturing and Materials Processing}, volume = {6}, journal = {Journal of Manufacturing and Materials Processing}, number = {5}, publisher = {MDPI}, address = {Basel}, issn = {2504-4494}, doi = {10.3390/jmmp6050093}, pages = {1 -- 12}, year = {2022}, abstract = {In times of short product life cycles, additive manufacturing and rapid tooling are important methods to make tool development and manufacturing more efficient. High-performance polymers are the key to mold production for prototypes and small series. However, the high temperatures during vulcanization injection molding cause thermal aging and can impair service life. The extent to which the thermal stress over the entire process chain stresses the material and whether it leads to irreversible material aging is evaluated. To this end, a mold made of PEEK is fabricated using fused filament fabrication and examined for its potential application. The mold is heated to 200 ◦C, filled with rubber, and cured. A differential scanning calorimetry analysis of each process step illustrates the crystallization behavior and first indicates the material resistance. It shows distinct cold crystallization regions at a build chamber temperature of 90 ◦C. At an ambient temperature above Tg, crystallization of 30\% is achieved, and cold crystallization no longer occurs. Additional tensile tests show a decrease in tensile strength after ten days of thermal aging. The steady decrease in recrystallization temperature indicates degradation of the additives. However, the tensile tests reveal steady embrittlement of the material due to increasing crosslinking.}, language = {en} } @article{EngemannCoenenDawaretal.2021, author = {Engemann, Heiko and C{\"o}nen, Patrick and Dawar, Harshal and Du, Shengzhi and Kallweit, Stephan}, title = {A robot-assisted large-scale inspection of wind turbine blades in manufacturing using an autonomous mobile manipulator}, series = {Applied Sciences}, volume = {11}, journal = {Applied Sciences}, number = {19}, publisher = {MDPI}, address = {Basel}, issn = {2076-3417}, doi = {10.3390/app11199271}, pages = {1 -- 22}, year = {2021}, abstract = {Wind energy represents the dominant share of renewable energies. The rotor blades of a wind turbine are typically made from composite material, which withstands high forces during rotation. The huge dimensions of the rotor blades complicate the inspection processes in manufacturing. The automation of inspection processes has a great potential to increase the overall productivity and to create a consistent reliable database for each individual rotor blade. The focus of this paper is set on the process of rotor blade inspection automation by utilizing an autonomous mobile manipulator. The main innovations include a novel path planning strategy for zone-based navigation, which enables an intuitive right-hand or left-hand driving behavior in a shared human-robot workspace. In addition, we introduce a new method for surface orthogonal motion planning in connection with large-scale structures. An overall execution strategy controls the navigation and manipulation processes of the long-running inspection task. The implemented concepts are evaluated in simulation and applied in a real-use case including the tip of a rotor blade form.}, language = {en} } @article{SchwarzGebhardtSchleseretal.2019, author = {Schwarz, Alexander and Gebhardt, Andreas and Schleser, Markus and Popoola, Patricia}, title = {New Welding Joint Geometries Manufactured by Powder Bed Fusion from 316L}, series = {Materials Performance and Characterization 8}, journal = {Materials Performance and Characterization 8}, number = {in press}, issn = {2379-1365}, doi = {10.1520/MPC20180096}, year = {2019}, language = {en} } @article{CosmaKesslerGebhardtetal.2020, author = {Cosma, Cosmin and Kessler, Julia and Gebhardt, Andreas and Campbell, Ian and Balc, Nicolae}, title = {Improving the Mechanical Strength of Dental Applications and Lattice Structures SLM Processed}, series = {Materials}, volume = {13}, journal = {Materials}, number = {4}, publisher = {MDPI}, address = {Basel}, issn = {1996-1944}, doi = {10.3390/ma13040905}, pages = {1 -- 18}, year = {2020}, abstract = {To manufacture custom medical parts or scaffolds with reduced defects and high mechanical characteristics, new research on optimizing the selective laser melting (SLM) parameters are needed. In this work, a biocompatible powder, 316L stainless steel, is characterized to understand the particle size, distribution, shape and flowability. Examination revealed that the 316L particles are smooth, nearly spherical, their mean diameter is 39.09 μm and just 10\% of them hold a diameter less than 21.18 μm. SLM parameters under consideration include laser power up to 200 W, 250-1500 mm/s scanning speed, 80 μm hatch spacing, 35 μm layer thickness and a preheated platform. The effect of these on processability is evaluated. More than 100 samples are SLM-manufactured with different process parameters. The tensile results show that is possible to raise the ultimate tensile strength up to 840 MPa, adapting the SLM parameters for a stable processability, avoiding the technological defects caused by residual stress. Correlating with other recent studies on SLM technology, the tensile strength is 20\% improved. To validate the SLM parameters and conditions established, complex bioengineering applications such as dental bridges and macro-porous grafts are SLM-processed, demonstrating the potential to manufacture medical products with increased mechanical resistance made of 316L.}, language = {en} } @article{EngemannDuKallweitetal.2020, author = {Engemann, Heiko and Du, Shengzhi and Kallweit, Stephan and C{\"o}nen, Patrick and Dawar, Harshal}, title = {OMNIVIL - an autonomous mobile manipulator for flexible production}, series = {Sensors}, volume = {20}, journal = {Sensors}, number = {24, art. no. 7249}, publisher = {MDPI}, address = {Basel}, isbn = {1424-8220}, doi = {10.3390/s20247249}, pages = {1 -- 30}, year = {2020}, language = {en} } @article{PfaffEnningSutter2022, author = {Pfaff, Raphael and Enning, Manfred and Sutter, Stefan}, title = {A risk‑based approach to automatic brake tests for rail freight service: incident analysis and realisation concept}, series = {SN Applied Sciences}, volume = {4}, journal = {SN Applied Sciences}, number = {4}, publisher = {Springer}, address = {Cham}, issn = {2523-3971}, doi = {10.1007/s42452-022-05007-x}, pages = {1 -- 14}, year = {2022}, abstract = {This study reviews the practice of brake tests in freight railways, which is time consuming and not suitable to detect certain failure types. Public incident reports are analysed to derive a reasonable brake test hardware and communication architecture, which aims to provide automatic brake tests at lower cost than current solutions. The proposed solutions relies exclusively on brake pipe and brake cylinder pressure sensors, a brake release position switch as well as radio communication via standard protocols. The approach is embedded in the Wagon 4.0 concept, which is a holistic approach to a smart freight wagon. The reduction of manual processes yields a strong incentive due to high savings in manual labour and increased productivity.}, language = {en} } @article{UlmerBraunChengetal.2022, author = {Ulmer, Jessica and Braun, Sebastian and Cheng, Chi-Tsun and Dowey, Steve and Wollert, J{\"o}rg}, title = {Gamification of virtual reality assembly training: Effects of a combined point and level system on motivation and training results}, series = {International Journal of Human-Computer Studies}, volume = {165}, journal = {International Journal of Human-Computer Studies}, number = {Art. No. 102854}, publisher = {Elsevier}, address = {Amsterdam}, issn = {1071-5819}, doi = {10.1016/j.ijhcs.2022.102854}, year = {2022}, abstract = {Virtual Reality (VR) offers novel possibilities for remote training regardless of the availability of the actual equipment, the presence of specialists, and the training locations. Research shows that training environments that adapt to users' preferences and performance can promote more effective learning. However, the observed results can hardly be traced back to specific adaptive measures but the whole new training approach. This study analyzes the effects of a combined point and leveling VR-based gamification system on assembly training targeting specific training outcomes and users' motivations. The Gamified-VR-Group with 26 subjects received the gamified training, and the Non-Gamified-VR-Group with 27 subjects received the alternative without gamified elements. Both groups conducted their VR training at least three times before assembling the actual structure. The study found that a level system that gradually increases the difficulty and error probability in VR can significantly lower real-world error rates, self-corrections, and support usages. According to our study, a high error occurrence at the highest training level reduced the Gamified-VR-Group's feeling of competence compared to the Non-Gamified-VR-Group, but at the same time also led to lower error probabilities in real-life. It is concluded that a level system with a variable task difficulty should be combined with carefully balanced positive and negative feedback messages. This way, better learning results, and an improved self-evaluation can be achieved while not causing significant impacts on the participants' feeling of competence.}, language = {en} } @article{LuftBremenLuft2023, author = {Luft, Angela and Bremen, Sebastian and Luft, Nils}, title = {A cost/benefit and flexibility evaluation framework for additive technologies in strategic factory planning}, series = {Processes}, volume = {11}, journal = {Processes}, number = {7}, publisher = {MDPI}, address = {Basel}, issn = {2227-9717}, doi = {10.3390/pr11071968}, pages = {Artikel 1968}, year = {2023}, abstract = {There is a growing demand for more flexibility in manufacturing to counter the volatility and unpredictability of the markets and provide more individualization for customers. However, the design and implementation of flexibility within manufacturing systems are costly and only economically viable if applicable to actual demand fluctuations. To this end, companies are considering additive manufacturing (AM) to make production more flexible. This paper develops a conceptual model for the impact quantification of AM on volume and mix flexibility within production systems in the early stages of the factory-planning process. Together with the model, an application guideline is presented to help planners with the flexibility quantification and the factory design process. Following the development of the model and guideline, a case study is presented to indicate the potential impact additive technologies can have on manufacturing flexibility Within the case study, various scenarios with different production system configurations and production programs are analyzed, and the impact of the additive technologies on volume and mix flexibility is calculated. This work will allow factory planners to determine the potential impacts of AM on manufacturing flexibility in an early planning stage and design their production systems accordingly.}, language = {en} } @article{Pfaff2023, author = {Pfaff, Raphael}, title = {Braking distance prediction for vehicle consist in low-speed on-sight operation: a Monte Carlo approach}, series = {Railway Engineering Science}, volume = {31}, journal = {Railway Engineering Science}, number = {2}, publisher = {SpringerOpen}, issn = {2662-4753 (eISSN)}, doi = {10.1007/s40534-023-00303-7}, pages = {135 -- 144}, year = {2023}, abstract = {The first and last mile of a railway journey, in both freight and transit applications, constitutes a high effort and is either non-productive (e.g. in the case of depot operations) or highly inefficient (e.g. in industrial railways). These parts are typically managed on-sight, i.e. with no signalling and train protection systems ensuring the freedom of movement. This is possible due to the rather short braking distances of individual vehicles and shunting consists. The present article analyses the braking behaviour of such shunting units. For this purpose, a dedicated model is developed. It is calibrated on published results of brake tests and validated against a high-definition model for low-speed applications. Based on this model, multiple simulations are executed to obtain a Monte Carlo simulation of the resulting braking distances. Based on the distribution properties and established safety levels, the risk of exceeding certain braking distances is evaluated and maximum braking distances are derived. Together with certain parameters of the system, these can serve in the design and safety assessment of driver assistance systems and automation of these processes.}, language = {en} } @article{AbbasHedwigBalcetal.2023, author = {Abbas, Karim and Hedwig, Lukas and Balc, Nicolae and Bremen, Sebastian}, title = {Advanced FFF of PEEK: Infill strategies and material characteristics for rapid tooling}, series = {Polymers}, volume = {2023}, journal = {Polymers}, number = {15}, publisher = {MDPI}, address = {Basel}, doi = {10.3390/polym15214293}, pages = {Artikel 4293}, year = {2023}, abstract = {Traditional vulcanization mold manufacturing is complex, costly, and under pressure due to shorter product lifecycles and diverse variations. Additive manufacturing using Fused Filament Fabrication and high-performance polymers like PEEK offer a promising future in this industry. This study assesses the compressive strength of various infill structures (honeycomb, grid, triangle, cubic, and gyroid) when considering two distinct build directions (Z, XY) to enhance PEEK's economic and resource efficiency in rapid tooling. A comparison with PETG samples shows the behavior of the infill strategies. Additionally, a proof of concept illustrates the application of a PEEK mold in vulcanization. A peak compressive strength of 135.6 MPa was attained in specimens that were 100\% solid and subjected to thermal post-treatment. This corresponds to a 20\% strength improvement in the Z direction. In terms of time and mechanical properties, the anisotropic grid and isotropic cubic infill have emerged for use in rapid tooling. Furthermore, the study highlights that reducing the layer thickness from 0.15 mm to 0.1 mm can result in a 15\% strength increase. The study unveils the successful utilization of a room-temperature FFF-printed PEEK mold in vulcanization injection molding. The parameters and infill strategies identified in this research enable the resource-efficient FFF printing of PEEK without compromising its strength properties. Using PEEK in rapid tooling allows a cost reduction of up to 70\% in tool production.}, language = {en} }