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As climate change accelerates, the demand for green energy is growing significantly. Due to the intermittent nature of renewable energy, the need for long-term storage is growing at the same rate. Hydrogen presents itself as a promising option for long-term storage, the need for electrolysis plants is therefore increasing significantly. Solutions for scaling up alkaline electrolysis production are currently lacking, particularly in the handling of large mesh electrodes. Therefore, new gripping concepts and technologies have to be developed to enable precise and automated handling of the electrodes, as established handling methods have failed due to the porous, limp and weakly magnetic material properties. This paper therefore presents two new ingressive gripping technologies in the form of individual gripping elements, which can later be combined to form a gripper. The technologies identified here are based on a threaded structure on the one hand and a spiral-like structure on the other. Depending on the mesh geometry to be handled, the gripper elements are designed accordingly. In order to grip the mesh, the gripping element is moved forward and turned at the same time. For verification, sample gripper elements were tested for a range of mesh geometries. The individual gripper elements were produced using selective Laser melting process (SLM), as the fine structures would be exceedingly challenging as well as very costly to produce using conventional manufacturing methods. The gripper elements were tested for three aspects of the handling process: Reliability, retention force and precision. The results in finer meshes show a high holding force for the spiral structures, while the screw structures show more potential in precision. In terms of performance in finer meshes, both structures have potential for use in mesh electrodes, with the low retention force of the screw structures due to the increasing imprecision of the SLM process.

Lightweight design and hybrid components enable innovative and new component concepts, especially when combining structurally reliable metal components with individualized polymer components. In this research, a process for additive manufacturing polymers on the surface of extruded aluminum profiles is examined. The extrusion process is adapted to produce foamable aluminum profiles, which can be utilized to enable a form fit between the two materials and ensures sufficient bond strength. For this purpose, a novel aluminum block material based on the standard wrought alloy EN AW-6082 was developed. It consists of a solid EN AW-6082 core and powder metallurgically produced outer layer, which allows local foaming of the aluminum profile surface. The main objective of this study was to optimize the bond strength of the hybrid aluminum-polymer components. The methods employed include fabricating aluminum test specimens, performing mechanical tests, x-ray microscopy to analyze the pore structure and evaluating the 3D pore distribution and the wall thickness. Virtual foam models were created to numerically investigate suitable pore sizes and foam geometries for form-fit with the polymer. The porosity achieved as a function of the processing of the components are discussed and a comparison is made between the real and virtual pore structures.

As climate change accelerates, the demand for green energy is growing significantly. Due to the intermittent nature of renewable energy, the need for long-term storage is growing at the same rate. Hydrogen presents itself as a promising option for long-term storage, the need for electrolysis plants is therefore increasing significantly. Solutions for scaling up alkaline electrolysis production are currently lacking, particularly in the handling of large mesh electrodes. Therefore, new gripping concepts and technologies have to be developed to enable precise and automated handling of the electrodes, as established handling methods have failed due to the porous, limp and weakly magnetic material properties. This paper therefore presents two new ingressive gripping technologies in the form of individual gripping elements, which can later be combined to form a gripper. The technologies identified here are based on a threaded structure on the one hand and a spiral-like structure on the other. Depending on the mesh geometry to be handled, the gripper elements are designed accordingly. In order to grip the mesh, the gripping element is moved forward and turned at the same time. For verification, sample gripper elements were tested for a range of mesh geometries. The individual gripper elements were produced using selective Laser melting process (SLM), as the fine structures would be exceedingly challenging as well as very costly to produce using conventional manufacturing methods. The gripper elements were tested for three aspects of the handling process: Reliability, retention force and precision. The results in finer meshes show a high holding force for the spiral structures, while the screw structures show more potential in precision. In terms of performance in finer meshes, both structures have potential for use in mesh electrodes, with the low retention force of the screw structures due to the increasing imprecision of the SLM process.

Lightweight design and hybrid components enable innovative and new component concepts, especially when combining structurally reliable metal components with individualized polymer components. In this research, a process for additive manufacturing polymers on the surface of extruded aluminum profiles is examined. The extrusion process is adapted to produce foamable aluminum profiles, which can be utilized to enable a form fit between the two materials and ensures sufficient bond strength. For this purpose, a novel aluminum block material based on the standard wrought alloy EN AW-6082 was developed. It consists of a solid EN AW-6082 core and powder metallurgically produced outer layer, which allows local foaming of the aluminum profile surface. The main objective of this study was to optimize the bond strength of the hybrid aluminum-polymer components. The methods employed include fabricating aluminum test specimens, performing mechanical tests, x-ray microscopy to analyze the pore structure and evaluating the 3D pore distribution and the wall thickness. Virtual foam models were created to numerically investigate suitable pore sizes and foam geometries for form-fit with the polymer. The porosity achieved as a function of the processing of the components are discussed and a comparison is made between the real and virtual pore structures.

Die neuen 3D-Entwurfs-, Berechnungs- und Fertigungsverfahren in Kombination mit dem Werkstoff ultrahochfester Beton (UHPC) bieten das Potenzial, den Beton-Leichtbau zu revolutionieren [1]. Die Herausforderung bei der Herstellung von geometrisch komplexen und hochpräzisen UHPC-Bauteilen liegt dabei im Schalungsbau. Da bisher keine verfügbaren abfallfreien und somit nachhaltigen alternativen Schalungsmaterialien bzw. -systeme identifiziert werden konnten, wurde der Forschungsansatz entwickelt, frei geformte Schalungen für Betonbauteile unter Verwendung von CNC-gefrästen recycelbaren Industriewachsen zu verwenden. Die Erforschung dieses Ansatzes hin zu einer anwendbaren Non-Waste-Schalungstechnologie wurde in einem gemeinsamen Forschungsprojekt des Instituts für Werkzeugmaschinen und Fertigungstechnik (IWF) und des Instituts für Tragwerksentwurf (ITE) der TU Braunschweig durchgeführt. Im Folgenden werden die wesentlichen Inhalte des Vorhabens, ausgehend von der Auswahl geeigneter Wachse, über die Untersuchung der Zerspanbarkeit bis hin zur Betonierung und anschließenden Analyse der Schalungen und Abgüsse, vorgestellt und diskutiert. Grundlegende Erkenntnisse wurden u. a. bereits 2016 in [2]–[5] veröffentlicht. Diese werden hier teilweise wiedergegeben und zudem mit zusätzlichen Informationen ergänzt. Die wesentlichen Erkenntnisse aus dem Forschungsvorhaben werden zusammengefasst. Ausführliche Informationen zur Entwicklung der Non-Waste-Wachsschalungstechnologie finden sich in der 2019 veröffentlichten Dissertation von Jeldrik Mainka [6]., The new 3D design, calculation and manufacturing methods in combination with ultra-high strength concrete (UHPC) off er the potential to revolutionise lightweight concrete construction [1]. The challenge in the production of geometrically complex and high-precision UHPC components lies in formwork construction. As no available waste-free and thus sustainable alternative formwork materials or systems have been identified so far, the research approach was developed to use freely shaped formwork for concrete components using CNC-milled recyclable industrial waxes. The research of this approach towards an applicable non-waste formwork technology was carried out in a joint research project of the Institute for Machine Tools and Production Engineering (IWF) and the Institute of Structural Design (ITE) of the Technical University of Braunschweig. In the following, the main contents of the project, starting with the selection of suitable waxes, the investigation of machinability up to the concreting and subsequent analysis of the formwork and castings are presented and discussed. Basic findings have already been published in 2016 in [2]–[5]. These are partly reproduced here and supplemented with additional information. The main findings of the research project are summarised. Detailed information on the development of non-waste wax formwork technology can be found in the dissertation by Jeldrik Mainka [6], published in 2019.

Die neuen 3D-Entwurfs-, Berechnungs- und Fertigungsverfahren in Kombination mit dem Werkstoff ultrahochfester Beton (UHPC) bieten das Potenzial, den Beton-Leichtbau zu revolutionieren [1]. Die Herausforderung bei der Herstellung von geometrisch komplexen und hochpräzisen UHPC-Bauteilen liegt dabei im Schalungsbau. Da bisher keine verfügbaren abfallfreien und somit nachhaltigen alternativen Schalungsmaterialien bzw. -systeme identifiziert werden konnten, wurde der Forschungsansatz entwickelt, frei geformte Schalungen für Betonbauteile unter Verwendung von CNC-gefrästen recycelbaren Industriewachsen zu verwenden. Die Erforschung dieses Ansatzes hin zu einer anwendbaren Non-Waste-Schalungstechnologie wurde in einem gemeinsamen Forschungsprojekt des Instituts für Werkzeugmaschinen und Fertigungstechnik (IWF) und des Instituts für Tragwerksentwurf (ITE) der TU Braunschweig durchgeführt. Im Folgenden werden die wesentlichen Inhalte des Vorhabens, ausgehend von der Auswahl geeigneter Wachse, über die Untersuchung der Zerspanbarkeit bis hin zur Betonierung und anschließenden Analyse der Schalungen und Abgüsse, vorgestellt und diskutiert. Grundlegende Erkenntnisse wurden u. a. bereits 2016 in [2]–[5] veröffentlicht. Diese werden hier teilweise wiedergegeben und zudem mit zusätzlichen Informationen ergänzt. Die wesentlichen Erkenntnisse aus dem Forschungsvorhaben werden zusammengefasst. Ausführliche Informationen zur Entwicklung der Non-Waste-Wachsschalungstechnologie finden sich in der 2019 veröffentlichten Dissertation von Jeldrik Mainka [6]., The new 3D design, calculation and manufacturing methods in combination with ultra-high strength concrete (UHPC) off er the potential to revolutionise lightweight concrete construction [1]. The challenge in the production of geometrically complex and high-precision UHPC components lies in formwork construction. As no available waste-free and thus sustainable alternative formwork materials or systems have been identified so far, the research approach was developed to use freely shaped formwork for concrete components using CNC-milled recyclable industrial waxes. The research of this approach towards an applicable non-waste formwork technology was carried out in a joint research project of the Institute for Machine Tools and Production Engineering (IWF) and the Institute of Structural Design (ITE) of the Technical University of Braunschweig. In the following, the main contents of the project, starting with the selection of suitable waxes, the investigation of machinability up to the concreting and subsequent analysis of the formwork and castings are presented and discussed. Basic findings have already been published in 2016 in [2]–[5]. These are partly reproduced here and supplemented with additional information. The main findings of the research project are summarised. Detailed information on the development of non-waste wax formwork technology can be found in the dissertation by Jeldrik Mainka [6], published in 2019.

The application of Industry 4.0 in lithium-ion battery cell production enables companies to achieve increased product quality and global competitiveness, since the majority of value creation takes place in this process. Studies have shown, that improving production performance is the most effective way for battery cell manufacturers to become competitive in the increasingly globalized market. To achieve operational excellence, battery manufacturers must adopt the concepts of networked and digitized production. However, holistically introducing digitalization, data systems and Industry 4.0 methods in all sectors of lithium-ion battery cell production currently poses a major challenge as comprehensive approaches are not available. Therefore, a tailored methodology for the evaluation of suitability and introduction of digitalization and Industry 4.0 is presented. The approach addresses all production-related sectors from logistics to plant engineering to quality management via so called application areas. Multiple development stages divide these into the maturity levels in terms of Industry 4.0. To design each application area and stage, Industry 4.0 use cases from battery cell producers, plant manufacturers, and battery-related research projects are clustered and abstracted for general accessibility. It is shown, that abstracted application areas may be assigned either to all production sectors such as communication or to specific fields such as quality methods. Based on the application areas, corresponding toolboxes are established forming the core of a digitalization guide. To increase the level of maturity with regard to Industry 4.0, the presented paper aims at enabling companies to apply appropriate tools from the toolbox to their production. The systematic and efficient development and implementation of digitalization as well as the holistic assessment of a company's maturity are enabled and provide an essential tool towards increased competitiveness.

Die neuen 3D-Entwurfs-, Berechnungs- und Fertigungsverfahren in Kombination mit dem Werkstoff ultrahochfester Beton (UHPC) bieten das Potenzial, den Beton-Leichtbau zu revolutionieren [1]. Die Herausforderung bei der Herstellung von geometrisch komplexen und hochpräzisen UHPC-Bauteilen liegt dabei im Schalungsbau. Da bisher keine verfügbaren abfallfreien und somit nachhaltigen alternativen Schalungsmaterialien bzw. -systeme identifiziert werden konnten, wurde der Forschungsansatz entwickelt, frei geformte Schalungen für Betonbauteile unter Verwendung von CNC-gefrästen recycelbaren Industriewachsen zu verwenden. Die Erforschung dieses Ansatzes hin zu einer anwendbaren Non-Waste-Schalungstechnologie wurde in einem gemeinsamen Forschungsprojekt des Instituts für Werkzeugmaschinen und Fertigungstechnik (IWF) und des Instituts für Tragwerksentwurf (ITE) der TU Braunschweig durchgeführt. Im Folgenden werden die wesentlichen Inhalte des Vorhabens, ausgehend von der Auswahl geeigneter Wachse, über die Untersuchung der Zerspanbarkeit bis hin zur Betonierung und anschließenden Analyse der Schalungen und Abgüsse, vorgestellt und diskutiert. Grundlegende Erkenntnisse wurden u. a. bereits 2016 in [2]–[5] veröffentlicht. Diese werden hier teilweise wiedergegeben und zudem mit zusätzlichen Informationen ergänzt. Die wesentlichen Erkenntnisse aus dem Forschungsvorhaben werden zusammengefasst. Ausführliche Informationen zur Entwicklung der Non-Waste-Wachsschalungstechnologie finden sich in der 2019 veröffentlichten Dissertation von Jeldrik Mainka [6]., The new 3D design, calculation and manufacturing methods in combination with ultra-high strength concrete (UHPC) off er the potential to revolutionise lightweight concrete construction [1]. The challenge in the production of geometrically complex and high-precision UHPC components lies in formwork construction. As no available waste-free and thus sustainable alternative formwork materials or systems have been identified so far, the research approach was developed to use freely shaped formwork for concrete components using CNC-milled recyclable industrial waxes. The research of this approach towards an applicable non-waste formwork technology was carried out in a joint research project of the Institute for Machine Tools and Production Engineering (IWF) and the Institute of Structural Design (ITE) of the Technical University of Braunschweig. In the following, the main contents of the project, starting with the selection of suitable waxes, the investigation of machinability up to the concreting and subsequent analysis of the formwork and castings are presented and discussed. Basic findings have already been published in 2016 in [2]–[5]. These are partly reproduced here and supplemented with additional information. The main findings of the research project are summarised. Detailed information on the development of non-waste wax formwork technology can be found in the dissertation by Jeldrik Mainka [6], published in 2019.

Overmoulding of thermoplastic composites combines the steps of thermoforming and injection moulding in an integrated manufacturing process. The combination of continuous fibre-reinforced thermoplastics with overmoulded polymer enables the manufacturing of highly func-tionally integrated structures with excellent mechanical properties. When performed as a one-shot process, an economically efficient manufacturing of geometrical complex lightweight parts within short cycle times is possible. However, a major challenge in the part and process design of over-moulded thermoplastic composites (OTC) is the assurance of sufficient bond strength between the composite and the overmoulded polymers. Within the framework of a simulation-based approach, this study aims to develop a methodology for predicting the bond strength in OTC using simulation data and a numerical model formulation of the bonding mechanisms. Therefore, a modelling approach for the determination of the bond strength depending on different process parameters is presented. In order to validate the bond strength model, specimens are manufactured with different process settings and mechanical tests are carried out. Overall, the results of the numerical computation are in good agreement with the experimentally determined bond strength. The proposed modelling approach enables the prediction of the local bond strength in OTC, considering the interface conditions and the processing history.

The bond strength between a thermoformed fibre reinforced thermoplastic sheet and an injected polymer is the limiting factor for the structural integrity of overmoulded thermoplastic composites. In this contribution, a simulation based digital twin of the thermoforming process is presented. From numerical parametric studies a reduced order model based on Proper Orthogonal Decomposition (POD) is developed. The combination with machine learning methods enables the real-time computation of arbitrary physical reliable temperature fields with sufficient accuracy to be used for design purposes and as inline quality gates.

Friction drilling is a widely used process to produce bushings in sheet materials, which are processed further by thread forming to create a connection port. Previous studies focused on the process parameters and did not pay detailed attention to the material flow of the bushing. In order to describe the material behaviour during a friction drilling process realistically, a detailed material characterisation was carried out. Temperature, strain rate, and rolling direction dependent tensile tests were performed. The results were used to parametrise the Johnson–Cook hardening and failure model. With the material data, numerical models of the friction drilling were created using the finite element method in 3D as well as 2D, and the finite volume method in 3D. Furthermore, friction drilling tests were carried out and analysed. The experimental results were compared with the numerical findings to evaluate which modelling method could describe the friction drilling process best. Highest imaging quality to reality was shown by the finite volume method in comparison to the experiments regarding the material flow and the geometry of the bushing.

Der sehr hohe Automatisierungsgrad innerhalb des Fahrzeugkarosseriebaus, die sehr hohen Qualitätsansprüche und die zunehmende Forderung nach einer produktflexiblen Produktion bilden einen Zielkonflikt, dessen Lösung mit marktverfügbaren Systemen derzeit nur unter erheblichen Einbußen hinsichtlich Taktzeit, Produktionsfläche und Wirtschaftlichkeit möglich ist. Die größten Herausforderungen bei der Flexibilisierung der Betriebsmittel des Karosseriebaus ergeben sich in Bezug auf die Entwicklung modellflexibler Geometrievorrichtungen, wobei die geometrischen und qualitativen Anforderungen bei der Fertigung von Fahrzeugtüren am größten sind. Für die modellübergreifende Produktion ohne Betriebsmittelaustausch wird in dieser Arbeit am Beispiel von Fahrzeugtüren eine Methode sowie eine konstruktive und technische Lösung für flexible Geometriespannvorrichtungen entwickelt. Durch softwaregestützte Analysen mit teilweise spezifisch entwickelten Softwareprogrammen, durch experimentelle Untersuchungen, sowie anhand empirischer Erfahrungen aus Gesprächen mit Anlagenbetreibern, Planern und Vorrichtungsbauern werden Methoden generiert, Anforderungen definiert und letztendlich standardisierte und modular einsetzbare Kinematiksysteme entwickelt. Anhand zweier umgesetzter Prototypen werden experimentelle Analysen zur Validierung der Anforderungen durchgeführt sowie abschließend mit Hilfe von Simulationsmethoden ein Regelungskonzept zur steuerungstechnischen Nachgiebigkeitskompensation der Kinematiksysteme entwickelt.:Bibliographische Beschreibung I Referat I Schlagworte I Vorwort II Inhaltsverzeichnis III Abkürzungsverzeichnis VI Kurzzeichenverzeichnis VIII Indizes X Abbildungsverzeichnis XI Tabellenverzeichnis XV Glossar XVI 1 Einleitung 1 2 Stand der Technik und Wissenschaft 4 2.1 Automobilproduktion und Karosseriebau 4 2.2 Anlagentechnik im Karosseriebau 5 2.2.1 Spannvorrichtungen im Karosseriebau 9 2.2.2 Grundaufbau der Vorrichtungskomponenten 12 2.2.3 Fahrzeugkoordinaten- und Ref

Overmoulding of thermoplastic composites combines the steps of thermoforming and injection moulding in an integrated manufacturing process. The combination of continuous fibre-reinforced thermoplastics with overmoulded polymer enables the manufacturing of highly func-tionally integrated structures with excellent mechanical properties. When performed as a one-shot process, an economically efficient manufacturing of geometrical complex lightweight parts within short cycle times is possible. However, a major challenge in the part and process design of over-moulded thermoplastic composites (OTC) is the assurance of sufficient bond strength between the composite and the overmoulded polymers. Within the framework of a simulation-based approach, this study aims to develop a methodology for predicting the bond strength in OTC using simulation data and a numerical model formulation of the bonding mechanisms. Therefore, a modelling approach for the determination of the bond strength depending on different process parameters is presented. In order to validate the bond strength model, specimens are manufactured with different process settings and mechanical tests are carried out. Overall, the results of the numerical computation are in good agreement with the experimentally determined bond strength. The proposed modelling approach enables the prediction of the local bond strength in OTC, considering the interface conditions and the processing history.

Der sehr hohe Automatisierungsgrad innerhalb des Fahrzeugkarosseriebaus, die sehr hohen Qualitätsansprüche und die zunehmende Forderung nach einer produktflexiblen Produktion bilden einen Zielkonflikt, dessen Lösung mit marktverfügbaren Systemen derzeit nur unter erheblichen Einbußen hinsichtlich Taktzeit, Produktionsfläche und Wirtschaftlichkeit möglich ist. Die größten Herausforderungen bei der Flexibilisierung der Betriebsmittel des Karosseriebaus ergeben sich in Bezug auf die Entwicklung modellflexibler Geometrievorrichtungen, wobei die geometrischen und qualitativen Anforderungen bei der Fertigung von Fahrzeugtüren am größten sind. Für die modellübergreifende Produktion ohne Betriebsmittelaustausch wird in dieser Arbeit am Beispiel von Fahrzeugtüren eine Methode sowie eine konstruktive und technische Lösung für flexible Geometriespannvorrichtungen entwickelt. Durch softwaregestützte Analysen mit teilweise spezifisch entwickelten Softwareprogrammen, durch experimentelle Untersuchungen, sowie anhand empirischer Erfahrungen aus Gesprächen mit Anlagenbetreibern, Planern und Vorrichtungsbauern werden Methoden generiert, Anforderungen definiert und letztendlich standardisierte und modular einsetzbare Kinematiksysteme entwickelt. Anhand zweier umgesetzter Prototypen werden experimentelle Analysen zur Validierung der Anforderungen durchgeführt sowie abschließend mit Hilfe von Simulationsmethoden ein Regelungskonzept zur steuerungstechnischen Nachgiebigkeitskompensation der Kinematiksysteme entwickelt.:Bibliographische Beschreibung I Referat I Schlagworte I Vorwort II Inhaltsverzeichnis III Abkürzungsverzeichnis VI Kurzzeichenverzeichnis VIII Indizes X Abbildungsverzeichnis XI Tabellenverzeichnis XV Glossar XVI 1 Einleitung 1 2 Stand der Technik und Wissenschaft 4 2.1 Automobilproduktion und Karosseriebau 4 2.2 Anlagentechnik im Karosseriebau 5 2.2.1 Spannvorrichtungen im Karosseriebau 9 2.2.2 Grundaufbau der Vorrichtungskomponenten 12 2.2.3 Fahrzeugkoordinaten- und Ref

Ziel der Arbeit ist die Entwicklung eines großserientauglichen mechanischen Aufrauverfahrens als Haftgrundvorbereitung thermisch gespritzter Zylinderlaufflächen in untereutektischen Aluminium-Zylinderkurbelgehäusen. Es wurde eine Kombination eines spanenden mit einem umformenden Prozess systematisch untersucht und ein Werkzeugkonzept sowie ein Oberflächenprofil ausgelegt. Für die Kontrolle des Profils wurde ein zerstörungsfreies, optisches Prüfverfahren entwickelt. Das Aufrauverfahren wurde durch Bearbeitungsversuche in der Prozesskette und im motorischen Betrieb auch praktisch validiert., This thesis focuses on a development of a mechanical roughening process that is suitable for large series production as an adhesion preparation for thermally sprayed cylinder surfaces in hypoeutectic aluminum cylinder blocks. A combination of a cutting and a forming process was systematically investigated and a tool concept as well as a surface profile were developed. A non-destructive, optical test method was implemented to check the profile. The roughening process was also practically validated by machining tests in the process chain and in motor operation.

Vacuum handling is a widespread technology in automated production systems for gripping of workpieces. Unfortunately, this solution accounts for a considerable share of industrial energy consumption. This consumption is mainly due to the losses in the involved steps like air compression, distribution, vacuum generation and gripper suction. However, the energy efficiency of vacuum handling systems is still relatively unexplored. The consortium partners are working together in the BiVaS project, which is funded by the Federal Ministry for Economic Affairs and Energy (BMWi). In this project, the drawback of high energy consumption is approached by the development of an energyefficient ejector, a biomimetic suction gripper as well as on system integration and the development of energy-efficient operating strategies and their energetic balancing in order to reduce the consumption of compressed air by 20 %. This reduction will be quantified experimentally in a pilot plant benchmark, where a realistic handling process is developed and examined. This paper shows the state of the art focusing on energy consumption of vacuum handling technology and the behaviour of the involved components during different handling operations. Furthermore, first biomimetic concepts and an estimation of the increase of energy efficiency will be presented for the running project.

Vacuum handling is a widespread technology in automated production systems for gripping of workpieces. Unfortunately, this solution accounts for a considerable share of industrial energy consumption. This consumption is mainly due to the losses in the involved steps like air compression, distribution, vacuum generation and gripper suction. However, the energy efficiency of vacuum handling systems is still relatively unexplored. The consortium partners are working together in the BiVaS project, which is funded by the Federal Ministry for Economic Affairs and Energy (BMWi). In this project, the drawback of high energy consumption is approached by the development of an energyefficient ejector, a biomimetic suction gripper as well as on system integration and the development of energy-efficient operating strategies and their energetic balancing in order to reduce the consumption of compressed air by 20 %. This reduction will be quantified experimentally in a pilot plant benchmark, where a realistic handling process is developed and examined. This paper shows the state of the art focusing on energy consumption of vacuum handling technology and the behaviour of the involved components during different handling operations. Furthermore, first biomimetic concepts and an estimation of the increase of energy efficiency will be presented for the running project.

Milling of ferrous metals is usually performed by applying cemented carbide tools due to their high hardness, temperature and wear resistance. Recently, ceramic tool materials have been on the rise and enhanced the efficiency in machining. As ceramics are brittle-hard materials, tool manufacturing requires a sound knowledge in order to meet the tool requirements such as sharp cutting edges and wear resistance. In this study, milling tools made of the high performance ceramic SiAlON were compared to tools made from cemented carbide. For both tool materials, the influence of a prepared cutting edge was investigated. Both the tool manufacturing process and the cutting edge preparation processes are presented, followed by the application of those tools within milling experiments. In order to evaluate the efficiency of both tool types, the cutting forces and the cumulative process energy demand were analyzed. Additionally, surface roughness of the machined workpieces and tool wear were examined. It was found that the ceramic tools, although process forces were higher than for cemented carbide tools, exhibited by far lower energy consumption, less tool wear and finally generated lower surface roughness. © 2020, The Author(s).

Within product development processes, computational models are used with increasing frequency. However, the use of those methods is often restricted to the area of focus, where product design, manufacturing process, and process chain simulations are regarded independently. In the use case of multi-material lightweight structures, the desired products have to meet several requirements regarding structural performance, weight, costs, and environment. Hence, manufacturing-related effects on the product as well as on costs and environment have to be considered in very early phases of the product development process in order to provide a computational concept that supports concurrent engineering. In this contribution, we present an integrated computational concept that includes product engineering and production engineering. In a multi-scale framework, it combines detailed finite element analyses of products and their related production process with process chain and factory simulations. Including surrogate models based on machine learning, a fast evaluation of production impacts and requirements can be realized. The proposed integrated computational product and production engineering concept is demonstrated in a use case study on the manufacturing of a multi-material structure. Within this study, a sheet metal forming process in combination with an injection molding process of short fiber reinforced plastics is investigated. Different sets of process parameters are evaluated virtually in terms of resulting structural properties, cycle times, and environmental impacts. © 2020, The Author(s).

Vacuum handling is a widespread technology in automated production systems for gripping of workpieces. Unfortunately, this solution accounts for a considerable share of industrial energy consumption. This consumption is mainly due to the losses in the involved steps like air compression, distribution, vacuum generation and gripper suction. However, the energy efficiency of vacuum handling systems is still relatively unexplored. The consortium partners are working together in the BiVaS project, which is funded by the Federal Ministry for Economic Affairs and Energy (BMWi). In this project, the drawback of high energy consumption is approached by the development of an energyefficient ejector, a biomimetic suction gripper as well as on system integration and the development of energy-efficient operating strategies and their energetic balancing in order to reduce the consumption of compressed air by 20 %. This reduction will be quantified experimentally in a pilot plant benchmark, where a realistic handling process is developed and examined. This paper shows the state of the art focusing on energy consumption of vacuum handling technology and the behaviour of the involved components during different handling operations. Furthermore, first biomimetic concepts and an estimation of the increase of energy efficiency will be presented for the running project.

Ziel der Arbeit ist die Entwicklung eines großserientauglichen mechanischen Aufrauverfahrens als Haftgrundvorbereitung thermisch gespritzter Zylinderlaufflächen in untereutektischen Aluminium-Zylinderkurbelgehäusen. Es wurde eine Kombination eines spanenden mit einem umformenden Prozess systematisch untersucht und ein Werkzeugkonzept sowie ein Oberflächenprofil ausgelegt. Für die Kontrolle des Profils wurde ein zerstörungsfreies, optisches Prüfverfahren entwickelt. Das Aufrauverfahren wurde durch Bearbeitungsversuche in der Prozesskette und im motorischen Betrieb auch praktisch validiert., This thesis focuses on a development of a mechanical roughening process that is suitable for large series production as an adhesion preparation for thermally sprayed cylinder surfaces in hypoeutectic aluminum cylinder blocks. A combination of a cutting and a forming process was systematically investigated and a tool concept as well as a surface profile were developed. A non-destructive, optical test method was implemented to check the profile. The roughening process was also practically validated by machining tests in the process chain and in motor operation.

Vacuum handling is a widespread technology in automated production systems for gripping of workpieces. Unfortunately, this solution accounts for a considerable share of industrial energy consumption. This consumption is mainly due to the losses in the involved steps like air compression, distribution, vacuum generation and gripper suction. However, the energy efficiency of vacuum handling systems is still relatively unexplored. The consortium partners are working together in the BiVaS project, which is funded by the Federal Ministry for Economic Affairs and Energy (BMWi). In this project, the drawback of high energy consumption is approached by the development of an energyefficient ejector, a biomimetic suction gripper as well as on system integration and the development of energy-efficient operating strategies and their energetic balancing in order to reduce the consumption of compressed air by 20 %. This reduction will be quantified experimentally in a pilot plant benchmark, where a realistic handling process is developed and examined. This paper shows the state of the art focusing on energy consumption of vacuum handling technology and the behaviour of the involved components during different handling operations. Furthermore, first biomimetic concepts and an estimation of the increase of energy efficiency will be presented for the running project.

Milling of ferrous metals is usually performed by applying cemented carbide tools due to their high hardness, temperature and wear resistance. Recently, ceramic tool materials have been on the rise and enhanced the efficiency in machining. As ceramics are brittle-hard materials, tool manufacturing requires a sound knowledge in order to meet the tool requirements such as sharp cutting edges and wear resistance. In this study, milling tools made of the high performance ceramic SiAlON were compared to tools made from cemented carbide. For both tool materials, the influence of a prepared cutting edge was investigated. Both the tool manufacturing process and the cutting edge preparation processes are presented, followed by the application of those tools within milling experiments. In order to evaluate the efficiency of both tool types, the cutting forces and the cumulative process energy demand were analyzed. Additionally, surface roughness of the machined workpieces and tool wear were examined. It was found that the ceramic tools, although process forces were higher than for cemented carbide tools, exhibited by far lower energy consumption, less tool wear and finally generated lower surface roughness. © 2020, The Author(s).

In this contribution, a computational approach for the manufacturing of multi-material lightweight parts is presented. For an efficient online optimization procedure, a proper orthogonal decomposition on offline obtained numerical results is carried out to construct a surrogate model. The functionality of the proposed framework is demonstrated on a use case study of a multi-material component consisting of a sheet metal basic structure and a plastic reinforcement structure. The manufacturing process chain consists of a deep drawing process followed by an injection molding process of short fiber reinforced plastics. The proposed methodology provides a fast and accurate computational model for structural properties with respect to the process settings.

Process planning for multi-axis forming presses is a particular challenge. This process provides the option to actively influencing the material flow in the forming process by defining a six dimensional tool motion path and the tool velocity. By comprehending this interaction, it is possible to control and thereby tailor the induced local material properties of the workpiece. Experiments were conducted with a multi-axis press, which is based on a Stewart platform. A simple plane workpiece geometry is chosen to analyse the flow behaviour and the temperature evolution of the glass mat thermoplastics (GMT) during the forming process. Subsequently, a numerical simulation of the multi-axis forming process is carried out and validated with the experimental data. The numerical analysis focuses on the material modelling as well as the prediction of the flow characteristics. Regarding material modelling of GMT, an extensive material characterization is performed to describe the flow behaviour. A prediction of the flow behaviour of GMT with reference to tool motion is enabled. For the FE simulation the element-free Galerkin method (EFG) is applied for modelling the fluid structure interaction and adaptive procedures.

The robot-assisted manufacturing is introduced for many years in automated production areas, while the production of buildings still follows the traditional manual process. Using new possibilities of digital planning the construction industry demonstrated potential for the implementation of freeform architectures, which are only possible using expensive and only once usable formwork structures. This paper focuses on sprayed concrete technology for automated production processes to build up freeform concrete components. A study case of the production of a concrete wall by an industrial robot, equipped with a concrete spraying tool is presented in order to investigate the possibilities and tolerancing issues of this technique.

The production rates of carbon fiber reinforced plastic (CFRP) parts are rising constantly which in turn drives research to bring a higher level of automation to the manufacturing processes of CFRP. Resin transfer molding (RTM), which is seen as a production method for high volumes, has been accelerated to a high degree. However, complex net-shape preforms are necessary for this process, which are widely manually manufactured. To face these challenges a new concept for the manufacturing of carbon fiber preforms with a form-flexible gripping, draping and joining end-effector is presented and discussed. Furthermore, this paper investigates the application of this concept, describes the initial build-up of a demonstrator, focusing on material selection and heating technology, and discusses test results with the prototype. This prototype already validates the feasibility of the proposed concept on the basis of a generic preform geometry. After a summary, this paper discusses future in-depth research concerning the concept and its application in more complex geometries. © 2015 by De Gruyter 2015.

Reactive multilayer systems (RMS) represent an innovative heat source for the establishment of solder joints. They offer fast bonding processes that introduce very little thermal input and internal stress on the bonded parts. The current application process of RMS is predominantly manual labor. There are a couple of challenges to be overcome to automate this process, a requirement for its introduction into industrial production. In this paper we evaluate the requirements for an automated joining process with RMS and devise a concept of a modular assembly system for different product structures. Furthermore we show our results in gently and reliably gripping and handling of RMS.

Battery systems of electric vehicles suffer from low energy densities as well as high masses and geometrical complexity. The absence of standards for battery cells and peripheral components in combination with large and distributed design spaces within passenger vehicles open up innumerable possibilities to design battery systems. The results are product specific and uneconomical assembly systems. This paper describes the work of the TU Braunschweig to create a methodology that generates and evaluates modular and easy to assemble battery systems based upon user requirements. This methodology gathers and links requirements between the priorities "lightweight design" and "high volume production" including a partly automated generation of CAD data. The generated concepts are directly used for assembly planning. The presented methodology therefore represents a simultaneous engineering approach that shortens development time and supports design engineers as well as process planners.

The assembly of limp, elastic or differently shaped objects poses a huge challenge which needs to be met by machine tools and the corresponding processes of handling, forming and joining. These processes are often carried out manually. This technological gap triggered the present work at the Technische Universität Braunschweig. A novel form-flexible handling tool (FormHand) is presented which focuses on the automation of these production steps taking into consideration the material behavior. The combination of the flexibility of both industrial robot and the FormHand end-effector allows for new processes appropriate for these materials. This article investigates the used materials of the granular filler and the cushion textile, the working states of FormHand and the use of online sensors for an automated process application.

The rising number of electric vehicles comes along with an increasing demand for Li-Ion batteries. As resources such as lithium are valuable it is economically worthwhile to recycle EV batteries. One of the first steps of every battery recycling process is the disassembly, which can be a quite time and cost consuming process and hence has to be planned properly. Using the battery of the hybrid car Audi Q5 as a case study, a planning approach for the disassembly will be discussed in this paper. Therefore, disassembly sequences will be derived from a priority matrix and a disassembly graph will be drawn up. Finally, recommendations for the design of the disassembly system and work stations will be given.

Battery systems of electric vehicles suffer from low energy densities as well as high masses and geometrical complexity. The absence of standards for battery cells and peripheral components in combination with large and distributed design spaces within passenger vehicles open up innumerable possibilities to design battery systems. The results are product specific and uneconomical assembly systems. This paper describes the work of the TU Braunschweig to create a methodology that generates and evaluates modular and easy to assemble battery systems based upon user requirements. This methodology gathers and links requirements between the priorities "lightweight design" and "high volume production" including a partly automated generation of CAD data. The generated concepts are directly used for assembly planning. The presented methodology therefore represents a simultaneous engineering approach that shortens development time and supports design engineers as well as process planners.

Reactive multilayer systems (RMS) represent an innovative heat source for the establishment of solder joints. They offer fast bonding processes that introduce very little thermal input and internal stress on the bonded parts. The current application process of RMS is predominantly manual labor. There are a couple of challenges to be overcome to automate this process, a requirement for its introduction into industrial production. In this paper we evaluate the requirements for an automated joining process with RMS and devise a concept of a modular assembly system for different product structures. Furthermore we show our results in gently and reliably gripping and handling of RMS.

The rising number of electric vehicles comes along with an increasing demand for Li-Ion batteries. As resources such as lithium are valuable it is economically worthwhile to recycle EV batteries. One of the first steps of every battery recycling process is the disassembly, which can be a quite time and cost consuming process and hence has to be planned properly. Using the battery of the hybrid car Audi Q5 as a case study, a planning approach for the disassembly will be discussed in this paper. Therefore, disassembly sequences will be derived from a priority matrix and a disassembly graph will be drawn up. Finally, recommendations for the design of the disassembly system and work stations will be given.

The assembly of limp, elastic or differently shaped objects poses a huge challenge which needs to be met by machine tools and the corresponding processes of handling, forming and joining. These processes are often carried out manually. This technological gap triggered the present work at the Technische Universität Braunschweig. A novel form-flexible handling tool (FormHand) is presented which focuses on the automation of these production steps taking into consideration the material behavior. The combination of the flexibility of both industrial robot and the FormHand end-effector allows for new processes appropriate for these materials. This article investigates the used materials of the granular filler and the cushion textile, the working states of FormHand and the use of online sensors for an automated process application.

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