Publications

Process Optimization through Thin Flash Prevention. Due to the good flow properties of aluminum, the material tends to flow into tool gaps during flashless precision forging and produce the so-called thin flash. For the industrial implementation of flashless precision forging processes, an innovative prediction method for thin flash as well as sealing concepts are to be developed in cooperation with an industrial partner. Simulative studies show that local form filling does not correlate with high pressure or an increased potential for thin flash.

thin flash, FEM-simulation, sealing concepts, precision forging, forming technology

Progressive digitalization and new technologies have had a major impact on the development of artificial intelligence (AI) in recent years. Particularly for companies in the skilled trades sector, the time factor is taking on an increasingly changing customer behavior, more complex and demanding tasks, and other challenges, the time factor is playing an increasingly decisive role.

artificial intelligence, craft, guideline

A new process chain for the manufacturing of load-adapted hybrid components is presented. The "Tailored Forming” process chain consists of a deposition welding process, hot forming, machining and an optional heat treatment. This paper focuses on the combination of laser hot-wire cladding with subsequent hot forming to produce hybrid components. The applicability is investigated for different material combinations and component geometries, e.g. a shaft with a bearing seat or a bevel gear. Austenitic stainless steel AISI 316L and martensitic valve steel AISI HNV3 are used as cladding materials, mild steel AISI 1022M and case hardening steel AISI 5120 are used as base materials. The resulting component properties after laser hot-wire cladding and hot forming such as hardness, microstructure and residual stress state are presented. In the cladding and the heat-affected zone, the hot forming process causes a transformation from a welding microstructure to a fine-grained forming microstructure. Hot forming significantly affects the residual stress state in the cladding the resulting residual stress state depends on the material combination.

laser hot-wire cladding, cladding, hot forming, residual stress, tailored forming

The digital development of spaces within the city of Hannover by means of a digital image makes it possible to cover the usage needs of spaces more efficiently and in line with the requirements. The crea-tion of a digital image, which develops new possibilities for access to public space, requires the use of different sensors such as LiDAR sensors and tracking cameras. In order to select suitable sensors that can be used with UAS, the requirements for the overall system are first defined, which are derived in functional requirements for the sensor technology. Subsequently, the degree of fulfilment of the functional requirements by the different sensors

5G, UAS, digital image, digital twin

In the non-circular rolling, the feasibility of rolling several mutually offset, locally non-round shaped elements into a
cylindrical semi-finished product are investigated. One sub-area of the investigations is the rolling of two elliptical
sections. From three different calculation concepts for the determination of the tool engraving, one was chosen for a
simulative parameter study. The main influencing variables, including the length and width of the engraving and a
process window, were identified.

forming technology, manufacturing technology, FEM

The temporally and spatially accurate display of information in augmented reality (AR) systems is essential for immersion and operational reliability when using the technology. We developed an assistant system using a head-mounted display (HMD) to hide visual restrictions on forklifts. We propose a method to evaluate the accuracy and latency of AR systems using HMD. For measuring accuracy, we compare the deviation between real and virtual markers. For latency measurement, we count the frame difference between real and virtual events. We present the influence of different system parameters and dynamics on latency and overlay accuracy.

augmented reality, image processing, driver assistance system, forklift trucks

Process monitoring strategies allow wear-related conditions of forging dies to be detected and predicted. The prediction of the wear condition allows intelligent maintenance strategies. This allows residual tool life to be fully utilized, scrap to be reduced and downtime to be calculated. The content of this article is an economic analysis for calculating the payback period of a process monitoring system.

forging, process monitoring, economic efficiency

During flat die rolling, two die plates pass each other and form the cylindrical semi-finished product enclosed within. Non-circular rolling examines the rolling of multiple, locally nonround geometries such as eccentrics. With the aid of statistical experimental design, a simulative parameter investigation has been carried out, main influencing variables have been recognised and process windows identified.

non-round, eccentric, flat jaw tools, preforms, intermediate forms, FEM

How can additively manufactured components be laser welded? Their layered structure makes the welding process more complicated than for conventionally produced parts. IPH and LZH are jointly researching how components can nevertheless be joined in a quality-assured manner.

Additive manufacturing, 3D printing, laser transmission welding, joining, quality

In manual solid forming, hand-guided forging tongs are used when processing forged parts. During the forging process, employees are physically stressed by high forging part weights and transmitted impacts. This physical stress leads to employee health limitations and increases absenteeism rates. Ergonomic forging tongs have been developed at IPH that lead to a relief of the forging employees.

ergonomics, forging tongs, forming technology, prevention

Factory planning can increase the productivity of manufacturing significantly, though the process is expensive when it comes to cost and time. In this paper, we propose an Unmanned Aerial Vehicle (UAV) framework that accelerates this process and decreases the costs. The framework consists of a UAV that is equipped with an IMU, a camera and a LiDAR sensor in order to navigate and explore unknown indoor environments. Thus, it is independent of GNSS and solely uses on-board sensors. The acquired data should enable a DRL agent to perform autonomous decision making, applying a reinforcement learning approach. We propose a simulation of this framework including several training and testing environments, that should be used for developing a DRL agent.

drone, UAS, deep reinforcement learning

In this paper, objective functions for the optimisation of modular conveyor systems will be introduced. Modular conveyor systems consist of conventional as well as modular conveyor hardware, which are arranged in form of matrix-like layouts. The aim of an ongoing research project is to provide small and medium-sized enterprises with a user-friendly decision support for the selection and planning of modular conveyor systems. For this purpose, the conveyor systems should be evaluated according to the objectives throughput and space requirement. Therefore, mathematical equations have been developed, which enable a fast and precise evaluation of layouts. The paper focuses mainly on the efficient calculation of the throughput. The result quality of the evaluation equations regarding the throughput was proven by a simulation of example systems.

modular conveyor, conveyor system evaluation, throughput analysis, layout optimisation, logistics

A volatile, non-transparent market environment leads to fluctuations in the load on production capacities in the manufacturing sector, which are reflected within production in the over- or underutilization of machines and persons. Small and midsized enterprises (SMEs) are expecting increasing volatility, which is accompanied by an increase in the frequency of market and economic cycles. For SMEs it is difficult to cope with these fluctuations. Capacity sharing platforms can be a solution for this challenge. Platforms are available in different forms, but not used by companies often, because of prevailing scepticism in different fields. Therefore, a methodology will be developed to provide a decision support for or against platform usage. Additionally, the platform type choice will be supported, and the changes of logistic and economic indicators will be considered. With this information companies can make a qualitative decision, and the existing inhibitions can be alleviated.

capacity sharing, decision support, supplier and consumer view, logistic and economic indicators

The results of the wear investigations will allow multidirectional processes in hot forging to be optimized in the future in a low-wear and economical manner. The determined, wear-inducing process parameters within the design guideline represent elementary basic knowledge which can be applied in a process-specific manner. In principle, the economic potential of multi-directional forging processes using of multi-directional forging processes using sliding dies depends on the application and the desired component geometries. Multi-directional forging processes forging processes offer great potential for savings and can be process design using the results obtained, they can achieve high tool life and have a positive influence on the competitive situation of companies. As a result costs for explicitly selected niche components with significantly higher with significantly increased complexity can be reduced in the future with manageable investment costs in the future. In addition to the process-specific optimization of the process parameters, in the future options for mold design adaptation with regard to local cooling or local cooling or thermal insulation of the slide-wedge wedge mechanics, in order to be able to use the systems in automated series automated series production.

Slide tools, process design, economic efficiency, solid forming

Progress is urgently needed in the energy transition - but there are always acceptance problems and lawsuits with renewable energies. In the project "WindGISKI", a geoinformation system based on artificial intelligence is to be developed, which addresses these issues. In a preliminary project, influencing factors within the area of conflict between species, environmental and climate protection have already been identified. An interdisciplinary team from science and industry is now taking the next step with the development of artificial intelligence.

wind energy, area selection, artificial intelligence

Additive manufacturing allows components to be manufactured flexibly. This manufacturing process is particularly suitable for products with a unique character. In the production of large components, which have previously been manufactured by casting, this offers the advantages of greater flexibility in design and the elimination of the need to build molds that are only used once for unique items. To manufacture large components additively, a consortium of five companies is developing a new 3D printer for XXL products. For quality assurance, IPH - Institut für Integrierte Produktion Hannover has implemented two monitoring systems. These capture the geometry using three laser line scanners and regulate the manufacturing process during printing using two different software systems.

XXL products, large components, additive manufacturing, 3D printing, quality control

Tailored forming is used to produce hybrid components in which the materials used are locally adapted to the diferent types of physical, chemical and tribological requirements. In this paper, a Tailored Forming process chain for the production of a hybrid shaft with a bearing seat is investigated. The process chain consists of the manufacturing steps laser hot-wire cladding, cross-wedge rolling, turning and deep rolling. A cylindrical bar made of mild steel C22.8 is used as the base material, and a cladding of the martensitic valve steel X45CrSi9-3 is applied in the area of the bearing seat to achieve the strength and hardness required. It is investigated how the surface and subsurface properties of the hybrid component, such as hardness, microstructure and residual stress state, change within the process chain. The results are compared with a previous study in which the austenitic stainless steel X2CrNiMo19-12 was investigated as a cladding material. It is shown that the residual stress state after hot forming depends on the thermal expansion coefcients of the cladding material.

Tailored forming, Residual stress, Laser hot-wire cladding, Deep rolling, Hybrid Components

The reorganization of factory objects in the restructuring of existing factories is associated with numerous challenges. This article provides an overview of possible conflicting goals and key factors influencing the success of the project.

Factories are subject to continuous change. Ever shorter development cycles in the manufacture of different products lead to an increased need for restructuring of affected manufacturing structures. In the context of factory planning projects, the focus is on the design of the layout under the influence of individual framework conditions. The relocation steps necessary for realization are usually determined only after the layout design has been completed. However, the planning and preparation of the relocation represents an independent project task with regard to the objectives and complexity. Within the scope of the research project on the "Development of a Method for the Optimal Planning of the Relocation of Factory Objects in the Course of the Realization of a New Factory Layout" (OptiFaU), fundamental interrelationships in the planning and execution of factory relocations are investigated and discussed with regard to their significance for the success of the project. The aim of the project is to provide planning persons (e.g. relocation service providers or factory planners) with a possibility to evaluate relocation alternatives.

relocation planning, project planning, scheduling, factory planning, reorganization

IPH has developed an algorithm for the automated design of rolling dies in the DFG project "Non-Circular Rolling". The researchers are using it to perform extensive parameter studies with a wide range of dies.

Non-circular rolling, cross wedge rolling, rolling dies, design, automation, algorithm

For more than half of the approximately 30,000 wind turbines in Germany, the 20-year EEG funding will end in the next ten years. It is still unclear what the optimal technical and economic strategies for end-oflife utilization might look like. The BMWK joint project „TransWind“ aims to analyze the end-of-life issue on a micro- and macro-level in a transdisciplinary manner to support stakeholders from politics, the wind industry, and the resource and recycling sector in the selection of end-of-life strategies.

wind turbines, end-of-life, ecology, dismantling, repowering, disassembly, recycling, XXL products

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