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Production Engineering OnlineFirst articles

23.01.2022 | Production Process Open Access

Influence of solidification rates and heat treatment on the mechanical performance and joinability of the cast aluminium alloy AlSi10Mg

In modern vehicle chassis, multi-material design is implemented to apply the appropriate material for each functionality. In spaceframe technology, both sheet metal and continuous cast are joined to castings at the nodal points of the chassis.

M. Neuser, O. Grydin, Y. Frolov, M. Schaper

17.01.2022 | Production Process

The role of thermal contribution in the design of AA2024 friction stir welded butt and lap joints: mechanical properties and energy demand

Although in recent times the use of solid-state welding processes as friction stir welding (FSW) has become increasingly widespread, for some joint morphologies, as lap joints, there are still significantly less data available on both process …

Davide Campanella, Giulia Marcon, Alberto Lombardo, Gianluca Buffa, Livan Fratini

12.01.2022 | Quality Assurance Open Access

Application of an edge detection algorithm for surface determination in industrial X-ray computed tomography

Surface determination is an essential step of the measurement process in industrial X-ray computed tomography (XCT). The starting point of the surface determination process step is a single grey value threshold within a voxel volume in …

Matthias Busch, Tino Hausotte

10.01.2022 | Production Process Open Access

Analysis of the interactions between joint and component properties during clinching

Clinching is a joining process that is becoming more and more important in industry due to the increasing use of multi-material designs. Despite the already widespread use of the process, there is still a need for research to understand the …

Christian Steinfelder, Johann Acksteiner, Christina Guilleaume, Alexander Brosius

07.01.2022 | Production Process Open Access

Numerical and experimental investigation of flat-clinch joint strength

The striving for energy savings by lightweight construction requires the combination of different materials with advantageous properties. For joining sheet metal components, clinching offers a good alternative to thermal joining processes. In …

Sandra Friedrich, Thoralf Gerstmann, Carolin Binotsch, Birgit Awiszus

31.12.2021 | Machine Tool Open Access

Investigation of the influence of varying tumbling strategies on a tumbling self-piercing riveting process

The increasing demands for the reduction of carbon dioxide emission require intensified efforts to increase resource efficiency. Especially in the mobility sector with large moving masses, resource savings can contribute enormously to the …

S. Wituschek, F. Kappe, M. Lechner

23.12.2021 | Production Process Open Access

Joining of CFRT-steel hybrid parts via hole-forming and subsequent pin caulking

In times of increasing global warming, the awareness of the necessity for significant CO2 reduction is growing. Especially in the transport and aerospace sector, lightweight construction has potential to achieve emission reduction goals by …

David Römisch, Julian Popp, Dietmar Drummer, Marion Merklein

23.12.2021 | Production Process Open Access

A contribution on versatile process chains: joining with adaptive joining elements, formed by friction spinning

Nowadays, manufacturing of multi-material structures requires a variety of mechanical joining techniques. Mechanical joining processes and joining elements are used to meet a wide range of requirements, especially on versatile process chains. Most …

Christian Wischer, Werner Homberg

23.12.2021 | Production Process Open Access

Holistic investigation chain for the experimental determination of fracture mechanical material parameters with special specimens

In addition to the classical strength calculation, it is important to design components with regard to fracture mechanics because defects and cracks in a component can drastically influence its strength or fatigue behavior. Cracks can propagate …

Deborah Weiß, Britta Schramm, Gunter Kullmer

22.12.2021 | Production Process Open Access

Application of reinforcement learning for the optimization of clinch joint characteristics

Due to increasing challenges in the area of lightweight design, the demand for time- and cost-effective joining technologies is steadily rising. For this, cold-forming processes provide a fast and environmentally friendly alternative to common …

Christoph Zirngibl, Fabian Dworschak, Benjamin Schleich, Sandro Wartzack

13.12.2021 | Machine Tool Open Access

Hybrid manufacturing of topology optimized machine tool parts through a layer laminated manufacturing method

Practical validation using the example of a bearing block

Load-oriented lightweight structures are commonly designed based on topology optimization. For machine tool parts, they enable the reduction of moving masses and therefore increase the resource and energy efficiency of production systems. However …

Nico Helfesrieder, Michael Neubauer, Armin Lechler, Alexander Verl

07.12.2021 | Assembly Open Access

Computed tomography investigation of the material structure in clinch joints in aluminium fibre-reinforced thermoplastic sheets

Recent developments in automotive and aircraft industry towards a multi-material design pose challenges for modern joining technologies due to different mechanical properties and material compositions of various materials such as composites and …

Benjamin Gröger, Daniel Köhler, Julian Vorderbrüggen, Juliane Troschitz, Robert Kupfer, Gerson Meschut, Maik Gude

04.12.2021 | Production Process Open Access

Process design of a novel combination of peel grinding and deep rolling

Grinding is mostly considered as a finishing operation by which a high surface quality is achieved. An increase in productivity is therefore limited by maintained surface properties such as the roughness or tensile residual stresses. Thus, a …

Berend Denkena, Alexander Kroedel, Tobias Gartzke

02.12.2021 | Production Process Open Access

Influence of dressing strategy on tool wear and performance behavior in grinding of forming tools with toric grinding pins

The performance of grinding tools in grinding processes and the resulting surface and subsurface properties depend on various factors. The condition of the grinding tool after dressing is one of these factors. However, the influence of the …

Berend Denkena, Alexander Krödel-Worbes, Michael Keitel, Philipp Wolters

29.11.2021 | Machine Tool Open Access

Experimental investigation into the implications of transmission errors for rack-and-pinion drives

Rack-and-pinion drives are the preferred option in the machine tool sector when long ranges of motion and high loads are involved. However, their shortcomings particularly include deficiencies in the achievable positioning and path accuracy. The …

Lukas Steinle, Armin Lechler, Michael Neubauer, Alexander Verl

24.11.2021 | Production Management

A structured methodology to support human–robot collaboration configuration choice

Human–robot collaboration (HRC) is a gradually consolidating paradigm of the modern industry which combines human and robot skills to make production more flexible. Since the effective implementation of HRC requires a careful analysis of different …

Riccardo Gervasi, Luca Mastrogiacomo, Domenico Augusto Maisano, Dario Antonelli, Fiorenzo Franceschini

10.11.2021 | Production Process

Double-sided self-pierce riveting with flat-bottom holes: a feasibility study

This paper is focused on solving the problems of positioning and alignment of rivets in double-sided self-pierce riveting by means of flat-bottom holes that are previously machined in the overlapped sheets with greater mechanical strength. The …

Luis M. Alves, Rafael M. Afonso, Patric T. Pereira, Paulo A. F. Martins

10.11.2021 | Machine Tool Open Access

A novel tool monitoring approach for diamond wire sawing

Mobile diamond wire sawing is a highly flexible, productive and, versatile cutting process. Accordingly, it is used in many areas, such as the dismantling of nuclear power plants or wind turbines. Despite the widespread use of the process, the …

Berend Denkena, Benjamin Bergmann, Björn-Holger Rahner

27.10.2021 | Machine Tool

Tool wear and remaining useful life (RUL) prediction based on reduced feature set and Bayesian hyperparameter optimization

Accurate prediction of machine tool wear is an essential part of modern and efficient manufacturing. In recent years, many studies have been carried out using machine learning algorithms, both traditional and deep learning; with the latter ones …

Fabio C. Zegarra, Juan Vargas-Machuca, Alberto M. Coronado

19.10.2021 | Computer Aided Engineering Open Access

An optical-flow-based monitoring method for measuring translational motion in infrared-thermographic images of AFP processes

This paper presents a novel method for a precise localization of the automated-fiber-placement head, without the need for a data access to the machine control. It is based on a sub-pixel accurate optical-flow-algorithm which determines information …

Berend Denkena, Carsten Schmidt, Marc Timmermann, Andreas Friedel