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Plastics are used today in many areas of the automotive, aerospace and mechanical engineering industries due to their lightweight potential and ease of processing. Additive manufacturing is applied more and more frequently, as it offers a high degree of design freedom and eliminates the need for complex tools. However, the application of additively manufactured components made of plastics have so far been limited due to their comparatively low strength. For this reason, processes that offer additional reinforcement of the plastic matrix using fibers made of high-strength materials have been developed. However, these components represent a composite of different materials produced on the basis of fossil raw materials, which are difficult to recycle and generally not biodegradable.
Therefore, this paper will explore the potential for new composite materials whose matrix consists of a bio-based plastic. In this investigation, it is assumed that the matrix is reinforced with a fibrous material made of natural fiber to significantly increase the strength. This potential material should offer a lightweight yet strong structure and be biodegradable after use under controlled conditions. Therefore, the state of the art in the use of bio-based materials in 3D printing is first presented. In order to determine the economic boundary conditions, the growth potentials for bio-based materials are analyzed. Also, the recycling prospects for bio-based plastics will also be highlighted. The greenhouse gas emissions and land use to be expected when using bio-based materials are also estimated. Finally, the degradability of the composites is discussed.
Additive manufacturing is a rapidly growing manufacturing process for which many new processes and materials are currently being developed. The biggest advantage is that almost any shape can be produced, while conventional manufacturing methods reach their limits. Furthermore, a lot of material is saved because the part is created in layers and only as much material is used as necessary. In contrast, in the case of machining processes, it is not uncommon for more than half of the material to be removed and disposed of. Recently, new additive manufacturing processes have been on the market that enables the manufacturing of components using the FDM process with fiber reinforcement. This opens up new possibilities for optimizing components in terms of their strength and at the same time increasing sustainability by reducing materials consumption and waste. Within the scope of this work, different types of test specimens are to be designed, manufactured and examined. The test specimens are tensile specimens, which are used both for standardized tensile tests and for examining a practical component from automotive engineering used in student project. This project is a vehicle designed to compete in the Shell Eco-marathon, one of the world’s largest energy efficiency competitions. The aim is to design a vehicle that covers a certain distance with as little fuel as possible. Accordingly, it is desirable to manufacture the components with the lowest possible weight, while still ensuring the required rigidity. To achieve this, the use of fiber-reinforced 3D-printed parts is particularly suitable due to the high rigidity. In particular, the joining technology for connecting conventionally and additively manufactured components is developed. As a result, the economic efficiency was assessed, and guidelines for the design of components and joining elements were created. In addition, it could be shown that the additive manufacturing of the component could be implemented faster and more sustainably than the previous conventional manufacturing.
Today, thermoforming moulds are mostly produced using conventional mould-building technologies (e.g. milling and drilling) and are made of metal (e.g. aluminium or steel) or hardwood. The tools thus produced are very robust, but are only cost-effective in mass production. For the production of small batches of thermoformed parts, there is a need for moulds which can be produced quickly and economically. A new approach which significantly reduces the production time and cost is the 3D printing process (3DP). The use of this technology to produce thermoforming moulds offers many new options in the geometries which can be manufactured, and in manufacturing time and costs. In a case study of a thermoformed part (a scaled automotive model), the pre-processing of the CAD model of a mould is demonstrated. The mould can be printed within a few hours, and is sufficiently heat-resistant for moulding processes. The important advantages of moulds printed in 3D, in comparison to moulds built using conventional technologies, are the ability to create any shape of channels for the vacuum and the simplification in the production of tool mock-ups. This paper also discusses the economics of the technique, such as a comparison of material costs and manufacturing costs in relation to conventional production technologies and materials.
Experimental and numerical investigations into the forming of tailored strips and tailored tubes
(2008)
Through the application of tailored strips and tailored tubes, the wall thickness of components can be manufactured in a load-optimised manner. Thus, it is also possible to optimise component weight. Prior to the application of tailored products, wall thicknesses and the respective degree of deformation as well as the welding seam position can be determined in a FEM (finite element method) simulation. These results are then verified in test series on transfer presses and tube bending machines, with the necessary tool adaptations being determined in the process. This results in weight and cost reductions for deep-drawn components and tube sections. Moreover, this means that especially with regard to tubes, multiple sections can be combined in one component. A feasibility study shows that the level of possible weight and cost savings depends on the respective component geometry and load situation. Additional costs for the production of tailored products and - if necessary - tool modifications also need to be considered. Thus, the amount of savings possible for a part can only be determined on an individual basis.
Um medizinische Behandlungsverfahren in der Praxis besser verstehen und anwenden zu können, gewinnt die Visualisierung der Prozesse an immer größerer Bedeutung. Durch Anwendung der Computer-Simulationssoftware CST können elektromagnetische und thermische Simulationen zur Analyse verschiedener Herzrhythmusstörungen durchgeführt werden. Eine weitere Form der Visualisierung erfolgt durch haptische, dreidimensionale Druckmodelle. Diese Modelle können mit einem generativen Herstellungsverfahren, wie z. B. einem 3D-Drucker, in kürzester Zeit hergestellt werden.
The Human-Robot-Collaboration (HRC) has developed rapidly in recent years with the help of collaborative lightweight robots. An important prerequisite for HRC is a safe gripper system. This results in a new field of application in robotics, which spreads mainly in supporting activities in the assembly and in the care. Currently, there are a variety of grippers that show recognizable weaknesses in terms of flexibility, weight, safety and price.
By means of Additive manufacturing (AM) gripper systems can be developed which can be used multifunctionally, manufactured quickly and customized. In addition, the subsequent assembly effort can be reduced due to the integration of several components to a complex component. An important advantage of AM is the new freedom in designing products. Thus, components using lightweight design can be produced. Another advantage is the use of 3D multi-material printing, wherein a component with different material properties and also functions can be realized.
This contribution presents the possibilities of AM considering HRC requirements. First of all, the topic of Human-Robot-Interaction with regard to additive manufacturing will be explained on the basis of a literature review. In addition, the development steps of the HRI gripper through to assembly are explained. The acquired knowledge regarding the AM are especially emphasized here. Furthermore, an application example of the HRC gripper is considered in detail and the gripper and its components are evaluated and optimized with respect to their function. Finally, a technical and economic evaluation is carried out. As a result, it is possible to additively manufacture a multifunctional and customized human-robot collaboration gripping system. Both the costs and the weight were significantly reduced. Due to the low weight of the gripping system only a small amount of about 13% of the load of the robot used is utilized.
Zur Herstellung von Spritzgussformeinsätzen kommen in der Regel spanende Verfahren zum Einsatz. In den letzten Jahren hat sich allerdings auch die additive Herstellung dieser Werkzeuge als zweckmäßig erwiesen. In der Produktentwicklung spielt die Agilität heute eine immer wichtigere Rolle. Um mögliche Potentiale des Additive Tooling im Rahmen des Agile Prototyping und um Unterschiede zu den konventionellen Herstellverfahren aufzuzeigen, werden Angebote für die Fertigung mehrerer Formeinsätze durch eine CNC- und HSC-Fertigung, sowie durch additive Herstellung angefragt und hinsichtlich Beschaffungskosten und -zeiten miteinander verglichen. Zudem erfolgt eine Bewertung der technischen Unterschiede. Aus diesen beiden Betrachtungen kann schließlich ein Profil über die drei Herstellverfahren abgeleitet werden, welches bei der anwendungsfallspezifischen Verfahrensauswahl unterstützen soll.
Fusion 360 – kurz und bündig
(2020)
Dieses Lehrbuch ermöglicht dem Anfänger in der 3D-Modellierung einen schnellen Einstieg in die Arbeit mit dem cloudbasierten CAD-System Autodesk® Fusion 360TM. Der Schwerpunkt liegt dabei auf den grundlegenden Funktionen zur Modellierung von Einzelteilen und dem Zusammenbau von Produkten, sowie in der Erstellung von einfachen technischen Zeichnungen. Dabei werden bei jedem Schritt die besonderen Anforderungen an eine 3D-Druck-gerechte Gestaltung erläutert und umgesetzt. Somit ist das Ergebnis dieser „Schritt für Schritt“-Anleitung die vollständige Modellierung eines Miniatur-Automobils, das am 3D-Drucker in ein reales Modell umgesetzt werden kann. Das didaktische Konzept ist so ausgelegt, dass alle Schritte für ein Selbststudium geeignet sind. Die vorliegende Auflage wurde komplett überarbeitet, sie basiert auf der neuen Benutzeroberfläche User Interface (UI) und enthält ein neues Kapitel zum CNC-Blechbiegen.
Additive manufacturing (AM) or 3D printing (3DP) has become a widespread new technology in recent years and is now used in many areas of industry. At the same time, there is an increasing need for training courses that impart the knowledge required for product development in 3D printing. In this article, a workshop on “Rapid Prototyping” is presented, which is intended to provide students with the technical and creative knowledge for product development in the field of AM. Today, additive manufacturing is an important part of teaching for the training of future engineers. In a detailed literature review, the advantages and disadvantages of previous approaches to training students are examined and analyzed. On this basis, a new approach is developed in which the students analyze and optimize a given product in terms of additivie manufacturing. The students use two different 3D printers to complete this task. In this way, the students acquire the skills to work independently with different processes and materials. With this new approach, the students learn to adapt the design to different manufacturing processes and to observe the restrictions of different materials. The results of these courses are evaluated through feedback in a presentation and a questionnaire.
Additive manufacturing (AM) and in particular the application of 3D multi material printing offers completely new production technologies thanks to the degree of freedom in design and the simultaneous processing of several materials in one component. Today's CAD systems for product development are volume-based and therefore cannot adequately implement the multi-material approach. Voxel-based CAD systems offer the advantage that a component can be divided into many voxels and different materials and functions can be assigned to these voxels. In this contribution two voxel-based CAD systems will be analyzed in order to simplify the AM on voxel level with different materials. Thus, a number of suitable criteria for evaluating voxel-based CAD systems are being developed and applied. The results of a technical-economic comparison show the differences between the voxel-based systems and disclose their disadvantages compared to conventional CAD systems. In order to overcome these disadvantages, a new method is therefore presented as an approach that enables the voxelization of a component in a simple way based on a conventional CAD model. The process chain of this new method is demonstrated using a typical component from product design. The results of this implementation of the new method are illustrated and analyzed.