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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.
Selective laser melting of metals: desktop machines open up new chances even for small companies
(2012)
Additive manufacturing (AM) of metal parts by using Selective Laser Melting (SLM) has become a powerful tool mostly in the area of automotive, aerospace engineering and others. Especially in the field of dentistry, jewelry and related branches that require individualized or even one-of-a-kind products, the direct digital manufacturing process opens up new ways of design and manufacturing. In these fields, mostly small and medium sized businesses (SME) are operating which do not have sufficient human and economic resources to invest in this technology. But to stay competitive, the application of AM can be regarded as a necessity. In this situation a new desktop machine (Realizer SLM 50) was introduced that cost about 1/3 of a shop floor SLM machine and promises small quality parts. To find out whether the machine really is an alternative for SMEs the University of Applied Science, Aachen, Germany, designed, build and optimized typical parts from the dentistry and the jewelry branches using CoCr and silver material, the latter being new with this application. The paper describes the SLM procedure and how to find and optimize the most important parameters. The test is accompanied by digital simulation in order to verify the build parameters and to plan future builds. The procedure is shown as well as the resulting parts made from CoCr and silver material.
Particle-Image-Velocimetry (PIV) in rotierenden Maschinen / Dues, M. ; Kallweit, S. ; Siekmann, H.
(1994)
The production and assembly of customized products increases the demand for flexible automation systems. One approach is to remove the safety fences that separate human and industrial robot to combine their skills. This collaboration possesses a certain risk for the human co-worker, leading to numerous safety concepts to protect him. The human needs to be monitored and tracked by a safety system using different sensors. The proposed system consists of a RGBD camera for surveillance of the common working area, an array of optical distance sensors to compensate shadowing effects of the RGBD camera and a laser range finder to detect the co-worker when approaching the work cell. The software for collision detection, path planning, robot control and predicting the behaviour of the co-worker is based on the Robot Operating System (ROS). A first prototype of the work cell shows that with advanced algorithms from the field of mobile robotics a very flexible safety concept can be realized: the robot not simply stops its movement when detecting a collision, but plans and executes an alternative path around the obstacle.
In the study, the process chain of additive manufacturing by means of powder bed fusion will be presented based on the material glass. In order to reliably process components additively, new concepts with different solutions were developed and investigated.
Compared to established metallic materials, the properties of glass materials differ significantly. Therefore, the process control was adapted to the material glass in the investigations. With extensive parameter studies based on various glass powders such as borosilicate glass and quartz glass, scientifically proven results on powder bed fusion of glass are presented. Based on the determination of the particle properties with different methods, extensive investigations are made regarding the melting behavior of glass by means of laser beams. Furthermore, the experimental setup was steadily expanded. In addition to the integration of coaxial temperature measurement and regulation, preheating of the building platform is of major importance. This offers the possibility to perform 3D printing at the transformation temperatures of the glass materials. To improve the component’s properties, the influence of a subsequent heat treatment was also investigated.
The experience gained was incorporated into a new experimental system, which allows a much better exploration of the 3D printing of glass. Currently, studies are being conducted to improve surface texture, building accuracy, and geometrical capabilities using three-dimensional specimen.
The contribution shows the development of research in the field of 3D printing of glass, gives an insight into the machine and process engineering as well as an outlook on the possibilities and applications.