Simulation Techniques in Manufacturing Technology - … · Simulation Techniques in Manufacturing...
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Seite 1 © WZL / IPT Simulation Techniques in Simulation Techniques in Manufacturing Technology Manufacturing Technology Introduction Aachen, October 21, 2005 Prof. Fritz Klocke, Dipl.-Ing. Peter Frank Seite 2 © WZL / IPT Outline Organisation Laboratory for Machine Tools and Production Engineering (WZL) Time Schedule Overview of the Lecture Examination Date Visit of the WZL Test Stands
Transcript of Simulation Techniques in Manufacturing Technology - … · Simulation Techniques in Manufacturing...
Seite 1© WZL / IPT
Simulation Techniques in Simulation Techniques in Manufacturing TechnologyManufacturing Technology
Introduction
Aachen, October 21, 2005
Prof. Fritz Klocke, Dipl.-Ing. Peter Frank
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Outline
Organisation
Laboratory for Machine Tools and Production Engineering (WZL)
Time Schedule
Overview of the Lecture
Examination Date
Visit of the WZL Test Stands
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Coordinator of the lecture: Dipl.-Ing. Peter FrankRoom no. 305, 54BTel.: 02 41 / 8 02 81 [email protected]
Chair of Manufacturing Technology: Chairleader
Prof. Dr.-Ing. Fritz KlockeRoom no. 305, 53BTel.: 02 41 / 8 02 74 [email protected]
Organisation
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Aachen University of Technology (RWTH)founded in 187030.946 students5.352 students of Mechanical Engineering
Laboratory for Machine Tools andProduction Engineering (WZL)
founded in 1906559 employees- 163 scientists- 169 technical staff- 237 undergraduates6.600m² both office area and manufacturingand research area
Fraunhofer Instituteof Production Technology IPT
founded in 1980336 employees- 70 scientists- 73 technical staff- 193 undergraduates
WZL
WZL shop floor
Fraunhofer IPT
Research Capacity of WZL/IPT
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Directory Board of WZL
Prof. Klocke
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Board of the WZL
Structure of the WZL
Res
earc
h G
rou
ps
Chair of Production Engineering
Enterprise DevelopmentChange ManagementCo-operation Management
Innovation ManagementProduct PlanningProduct Development
Production ManagementFactory PlanningProduction Optimisation
Chair of ManufacturingTechnology
Principles of CuttingTechnologies
Cutting with GeometricallyDefined Cutting Edges
Cutting with GeometricallyUndefined Edges
Electro Machining
Metal Forming
Chair of Machine Tools
Machine TechnologyMachine InvestigationDesign and CalculationMachine elements
Controlling andAutomation
Drives and DiagnosisNC-TechnologyEngineering and UserSupportProduction Automation
Chair of Metrology andQuality Management
MetrologyDevelopment and Optimization of Measuring TechnologiesDesign and Integration of Measuring Procedures
Quality ManagementQuality ManagementSystemsMethods, Strategies and Computer Support of Quality Management
Gear Technology
Gear Calculation
Gear Investigation
Gear Production
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Chair of Manufacturing Technology
Core Activities:
Principles of production processes
Process studies
- machining with geometrically
defined cutting edges
- machining with geometrically
undefined cutting edges
- electro-discharge and electro-
chemical machining processes
- metal forming production
processes
- gear-manufacturing
Process monitoring
Process simulation
Environmentally compatible technologies
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Chair of Machine ToolsCore Activities:
Machine tools, handling systems and theircomponents
Computation and optimisation of thestatic, dynamic and thermal behaviourof machine tools
Metrological studies and evaluationof machine tool and handlingsystembehaviour
Control technology for machine-tools and manufacturing systems
Components and software forproduction automation
Programming, operating and controlsoftware systems for industrial robots
Gear optimisation
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Chair of Metrology and Quality Management
Core Activities:
Development and pratice-orientedoptimization of measuring methods and instrumentation for manufacturing metrology
Production-integrated metrology andquality control loops in theshop floor.
Intergration of measuring proceduresto simplify continous quality inspection
and testing
Quality management systems
Methods, strategies and computer support ofquality management
Seminars and lectures on actual topics in thefield of quality management
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Chair of Production Engineering
Core Activities:
Integrated product and process design
Co-operative value adding
Modelling
EDP-system improvement
Technology planning
Technology intelligence
Factory planning
Order processing
Technical and economicevaluation
EDP-system selection
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Time schedule
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Simulation Techniques in M. T.• Bulk forming I
Atomistic and macroscopic view of metal structures
28.10.05Lecture 2
Content
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Simulation Techniques in M. T.• Bulk forming II
Future developments: Improving prediction of ductile fracture
04.11.05Lecture 3
Content
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Simulation Techniques in M. T. Sheet metal forming
The Audi A2 Aluminum Spaceframe
cast ingprofilesheet metal
Source: Schuler
11.11.05Lecture 4
Content
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Simulation Techniques in M. T.Blanking and Fine Blanking
Fine blanked parts
18.11.05Lecture 5
Content
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Simulation Techniques in M. T.Computer excercise
Commercial FE codes for sheet metal forming
2D Modelling of selected cross sections:
• Abaqus www.abaqus.com• Ansys www.ansys.com• Autoform 2D www.autoform.ch• Deform 2D www.deform.com• Marc www.marc.com•...
Advantages:
• reduced computation time• less sensitive to quality of input data• usually less input data required
Disadvantages:
• difficult selection of cross sections to be modelled• less accurate results
Source: BMW / Fontana Pietro SPA
25.11.05Excercise
Content
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Machining with geometrically defined cutting edges
Simulation Techniques in M. T.Principles of Cutting
02.12.05Lecture 6
direction offeed motion
chip
tool
directionof primary
motionflank
workpiece
h thicknesshch chip thicknessαo tool orthogonal clearanceβo tool orthogonal wedge angleγo tool orthogonal rake
face
cvr
fvr
chh
h oβoα
oγ
Content
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Tools for internal and external turning operations
source: SECO
Simulation Techniques in M. T.Cutting Processes
09.12.05Lecture 7
Content
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Aim of Simulating the Cutting Process
„A 3D model for the prediction of
• Cutting Temperatures
• Cutting Forces
• Tool Wear
• Chip Formation
• Surface Integrity
with an easy to handle software tool.“
Mach
inability
Simulation Techniques in M. T.FE-Simulation of Cutting Processes
16.12.05Lecture 8
Content
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Basics of the cutting engagement
Tools
grit materials
Bondings
Tool manufacturing
Proceedings of tool manufacturing
Overview over the contents
I II III
hcu hcu eff
Ve
η
Tµ
FnS
FtS
bulage
chip
grain
Simulation Techniques in M. T.Grinding I
13.01.06Lecture 9
Content
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Which simulation techniques are used?
Penetration calculation Discontinious tooth form grinding
Finite Element Method Radial extension of grinding wheels
Artificial Neuronal Network Modelling of grinding processes
Genetic Algorithms Extrapolation of grinding results P
rogra
mm
-
man
agem
ent
Input
Data base
Output
ANN
GA
Simulation Techniques in M. T.Grinding II
20.01.06Lecture 10
Content
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Benefit of Virtual Reality
What benefit do you have? 20% reduction of physical prototypes
Reduction of constructional fault
Shorter product development time
higher product quality
improvement of communication in interdisciplinary teams
faster and cheaper check of different versionse.g. DaimlerChrysler has 8 different versions of a new carwhich are evaluated with VR, only 3 versions are build as
physicalprototypes crash analysis from FEM
Source: Fraunhofer IPT
Source: Fraunhofer IPT
Simulation Techniques in M. T.Virtual Reality / Rapid Prototyping
27.01.06Lecture 11
Content
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Motivation
optimisedadjustment
M T
S
enterprise
optimisedadjustment
M T
S
enterprise
optimisedadjustment
M T
S
information certainty
resource consumption
change inherent potential planning depthpre-determination of costs
product design processS: shape, T: technology, M: material
level 1 level 2 level 3
Simulation Techniques in M. T.Process chains
03.02.06Lecture 12
Content
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Date of the examination: 28th March 2006, 9:00 am - 11:00 amRoom no. 413, Steinbachstr. 54a
Working time: 120 Min
Lecture notes: Download from:www.wzl.rwth-aachen.de
In paper from:Mr. FaymonvilleRoom no. 009Tuesday and Thurdayfrom 1 pm - 2 pm
Examination
