TY - JOUR A1 - Abbas, Karim A1 - Hedwig, Lukas A1 - Balc, Nicolae A1 - Bremen, Sebastian T1 - Advanced FFF of PEEK: Infill strategies and material characteristics for rapid tooling JF - Polymers N2 - 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. KW - polyetheretherketone (PEEK) KW - rapid tooling KW - infill strategy KW - compression behavior KW - additive manufacturing KW - fused filament fabrication Y1 - 2023 U6 - http://dx.doi.org/10.3390/polym15214293 N1 - This article belongs to the Special Issue "Polymer Materials and Design Processes for Additively Manufactured Products" VL - 2023 IS - 15 PB - MDPI CY - Basel ER - TY - JOUR A1 - Luft, Angela A1 - Luft, Nils A1 - Arntz, Kristian T1 - A basic description logic for service-oriented architecture in factory planning and operational control in the age of industry 4.0 JF - Applied Sciences N2 - Manufacturing companies across multiple industries face an increasingly dynamic and unpredictable environment. This development can be seen on both the market and supply side. To respond to these challenges, manufacturing companies must implement smart manufacturing systems and become more flexible and agile. The flexibility in operational planning regarding the scheduling and sequencing of customer orders needs to be increased and new structures must be implemented in manufacturing systems’ fundamental design as they constitute much of the operational flexibility available. To this end, smart and more flexible solutions for production planning and control (PPC) are developed. However, scheduling or sequencing is often only considered isolated in a predefined stable environment. Moreover, their orientation on the fundamental logic of the existing IT solutions and their applicability in a dynamic environment is limited. This paper presents a conceptual model for a task-based description logic that can be applied to factory planning, technology planning, and operational control. By using service-oriented architectures, the goal is to generate smart manufacturing systems. The logic is designed to allow for easy and automated maintenance. It is compatible with the existing resource and process allocation logic across operational and strategic factory and production planning. KW - manufacturing data model KW - production planning and control KW - manufacturing flexibility KW - technology planning KW - SOA KW - service-oriented architectures KW - factory planning Y1 - 2023 U6 - http://dx.doi.org/10.3390/app13137610 N1 - This article belongs to the Special Issue "Smart Industrial System" VL - 2023 IS - 13 PB - MDPI CY - Basel ER - TY - JOUR A1 - Ulmer, Jessica A1 - Braun, Carsten A1 - Cheng, Chi-Tsun A1 - Dowey, Steve A1 - Wollert, Jörg T1 - A human factors-aware assistance system in manufacturing based on gamification and hardware modularisation JF - International Journal of Production Research N2 - Assistance systems have been widely adopted in the manufacturing sector to facilitate various processes and tasks in production environments. However, existing systems are mostly equipped with rigid functional logic and do not provide individual user experiences or adapt to their capabilities. This work integrates human factors in assistance systems by adjusting the hardware and instruction presented to the workers’ cognitive and physical demands. A modular system architecture is designed accordingly, which allows a flexible component exchange according to the user and the work task. Gamification, the use of game elements in non-gaming contexts, has been further adopted in this work to provide level-based instructions and personalised feedback. The developed framework is validated by applying it to a manual workstation for industrial assembly routines. KW - Human factors KW - assistance system KW - gamification KW - adaptive systems KW - manufacturing Y1 - 2023 U6 - http://dx.doi.org/10.1080/00207543.2023.2166140 SN - 0020-7543 (Print) SN - 1366-588X (Online) PB - Taylor & Francis ER - TY - JOUR A1 - Reisgen, Uwe A1 - Schleser, Markus A1 - Mokrov, Oleg A1 - Ahmed, Essam T1 - Uni- and bi-axial deformation behavior of laser welded advanced high strength steel sheets JF - Journal of materials processing technology N2 - Bead-on-plate butt joints of 2.5 mm hot rolled DP600/DP600 and 1.2 mm cold rolled TRIP700/TRIP700 steel sheets were performed using 6 kW CO2 laser beam welding. The welding speed ranged from 1.5 to 3.0 and from 2.1 to 3.9 m/min in DP/DP and TRIP/TRIP steel weldments respectively. A top surface helium gas was used as a shielding gas at a flow rate of 20 l/min. Metallographic examinations and transverse tensile testing (DIN EN 895: 1995) were carried out to characterize the weldments. The formability of base metals and weldments were investigated by standard Erichsen test (DIN EN ISO 20482). It was found that the uniaxial plastic behavior of both DP600 and TRIP700 base metals was in agreement with Swift and modified Mecking–Kocks models respectively. In a perpendicular tensile test to the weld line, all specimens were fractured at the base metal however the strengths were somewhat higher than those of base metal. There was a significant reduction in formability caused by welding of both DP/DP and TRIP/TRIP steel weldments and the formability has been improved with the increase of the welding speed. Y1 - 2010 U6 - http://dx.doi.org/http10.1016/j.jmatprotec.2010.08.003 SN - 0924-0136 VL - 210 IS - 15 SP - 2188 EP - 2196 PB - Elsevier CY - Amsterdam ER - TY - JOUR A1 - Mukherjee, Krishnendu A1 - Prahl, Ulrich A1 - Bleck, Wolfgang A1 - Reisgen, Uwe A1 - Schleser, Markus A1 - Abdurakhmanov, Aydemir T1 - Characterization and modelling techniques for gas metal arc welding of DP 600 sheet steels JF - Materialwissenschaft und Werkstofftechnik N2 - The objectives of the present work are to characterize the Gas Metal Arc Welding process of DP 600 sheet steel and to summarize the modelling techniques. The time-temperature evolution during the welding cycle was measured experimentally and modelled with the softwaretool SimWeld. To model the phase transformations during the welding cycle dilatometer tests were done to quantify the parameters for phase field modelling by MICRESS®. The important input parameters are interface mobility, nucleation density, etc. A contribution was made to include austenite to bainite transformation in MICRESS®. This is useful to predict the microstructure in the fast cooling segments. The phase transformation model is capable to predict the microstructure along the heating and cooling cycles of welding. Tensile tests have shown the evidence of failure at the heat affected zone, which has the ferrite-tempered martensite microstructure. Y1 - 2010 U6 - http://dx.doi.org/10.1002/mawe.201000692 SN - 1521-4052 VL - 41 IS - 11 SP - 972 EP - 983 PB - Wiley-VCH CY - Weinheim ER - TY - JOUR A1 - Reisgen, Uwe A1 - Schleser, Markus A1 - Mokrov, Oleg A1 - Ahmed, Essam T1 - Shielding gas influences on laser weldability of tailored blanks of advanced automotive steels JF - Applied surface science N2 - The effects of shielding gas types and flow rates on CO2 laser weldability of DP600/TRIP700 steel sheets were studied in this work. The evaluated shielding gases were helium (He), argon (Ar) and different mixtures of He and Ar. Weld penetration, tensile strength and formability (Erichsen test) of laser welds were found to be strongly dependent upon the shielding gas types. The ability of shielding gas in removing plasma plume and thus increasing weld penetration is believed to be closely related to ionization potential and atomic weight which determine the period of plasma formation and disappearance. It was found that the higher helium shielding gas flow rate, the deeper weld penetration and the lower weld width. Y1 - 2010 U6 - http://dx.doi.org/10.1016/j.apsusc.2010.08.042 SN - 0169-4332 (E-Journal); 0169-4332 (Print) VL - 257 IS - 5 SP - 1401 EP - 1406 PB - Elsevier CY - Amsterdam ER - TY - JOUR A1 - Ahmed, Essam A1 - Reisgen, Uwe A1 - Schleser, Markus A1 - Mokrov, Oleg T1 - On formability of tailor laser welded blanks of DP/TRIP steel sheets JF - Science and technology of welding and joining N2 - This paper aims to evaluate the formability of tailor welded blanks of dual phase (DP600)/transformation induced plasticity (TRIP700) steel sheets. In this work, bead on plate butt joints of 2·5 mm DP600 and 1·2 mm TRIP700 steel sheets were performed using CO2 laser beam welding. Microhardness measurements and transverse tensile testing were carried out to characterise the welds. The formability of base metals and welds were investigated by standard Erichsen test. In a perpendicular tensile test to the weld line, all specimens were fractured at the TRIP base metal, and the strengths were somewhat higher than those of base metal. There was a significant reduction in formability caused by welding of the DP600/TRIP700 steel sheets, and the formability increased with increasing welding speed. Y1 - 2010 U6 - http://dx.doi.org/10.1179/136217110X12731414739754 SN - 1743-2936 VL - 15 IS - 5 SP - 337 EP - 342 PB - Maney CY - Leeds ER - TY - JOUR A1 - Haselgruber, Nikolaus A1 - Mautner, Karin A1 - Thiele, Jan T1 - Usage Space Analysis for Reliability Testing JF - Quality and Reliability Engineering International N2 - During the development process of a complex technical product, one widely used and important technique is accelerated testing where the applied stress on a component is chosen to exceed the reference stress, i.e. the stress encountered in field operation, in order to reduce the time to failure. For that, the reference stress has to be known. Since a complex technical product may fail regarding numerous failure modes, stress in general is highly dimensional rather than scalar. In addition, customers use their products individually, i.e. field operation should be described by a distribution rather than by one scalar stress value. In this paper, a way to span the customer usage space is shown. It allows the identification of worst case reference stress profiles in significantly reduced dimensions with minimal loss of information. The application example shows that even for a complex product like a combustion engine, stress information can be compressed significantly. With low measurement effort it turned out that only three reference stress cycles were sufficient to cover a broad range of customer stress variety. Y1 - 2010 U6 - http://dx.doi.org/10.1002/qre.1155 SN - 1099-1638 N1 - Special Issue: Business and Industrial Statistics: Developments and Industrial Practices in Quality and Reliability VL - 26 IS - 8 SP - 877 EP - 885 PB - Wiley CY - New York ER -