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Prediction of the shape accuracy of parts fabricated by means of FLM process using FEM simulations

Möhring H.-Christian, Stehle Thomas, Maucher Clemens, Becker Dina, Braun Steffen

Journal of Machine Engineering

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2019

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Vol. 19, No. 1

114--127

EN

The prediction of component properties from the Additive manufacturing (AM) process poses a challenge. Therefore, this paper presents the development of a novel machine data (G-Code) based procedure as well as its programming implementation of a process simulation in ANSYS Mechanical for the fused layer modelling (FLM) process. For this purpose, an investigation of additively produced components with varying parameters made of polylactic acid (PLA) is carried out and simulated by means of the developed method. Application of the developed method makes it possible to predict the thermally induced distortion of PLA-Parts based on the machine data from the FLM process before production.

2

Lightweight machine enclosures for dynamic and efficient production processes

Möhring H.-Christian, Stehle Thomas, Schneider Matthias

Journal of Machine Engineering

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2019

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Vol. 19, No. 2

46--53

EN

Usually machining centres for processing wood-based and composite materials have moving partial machine enclosures in the X-axis direction. Because the workpieces to be machined are often large (e.g. aircraft doors), these partial enclosures have prevailed on the market compared to voluminous complete enclosures. Owing to the general trend towards complete machining through process integration, an increasing number of additional units are integrated into machining centres in addition to the main spindle. This leads to an increase of the mass to be moved as well as a larger and thus heavier partial enclosure. This inevitable increase in mass leads to a deterioration of the dynamic properties of the machine. To counteract this increase in mass, the use of lightweight design materials for machine enclosures becomes in the focus of attention. The lightweight materials to be used must comply with the requirements of modern mechanical engineering and legislation: retention in the event of tool breakage, reduction in the noise exposure of the machine environment and cost-effective solutions compared to the materials used nowadays. The sheet steel used today as material for partial enclosures is therefore to be supplemented or replaced with suitable lightweight design materials. Different lightweight materials are qualified for suitability as machine enclosure. Apart from mass reduction, ecological as well as economic aspects of the used materials play an important role. For this purpose, the safety properties (impact resistance in case of tool breakage / collision) of these weight-reduced materials have to be determined. In addition, an improvement in the acoustic behaviour of the machine is achieved by the new lightweight materials since the machine enclosure shields the distinctive sound sources.

3

En route to intelligent wood machining – current situation and future perspectives

Möhring H.-Christian, Eschelbacher Sarah, Güzel Kamil, Kimmelmann Martin, Schneider Matthias, Zizelmann Christoph, Häusler Andreas, Menze Christian

Journal of Machine Engineering

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2019

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Vol. 19, No. 4

5--26

EN

Wood materials are an important part of our daily life. Besides furniture, doors and window elements, parquet floors, veneering, ply wood, chip- and fibreboards, also structural elements for buildings are typical products. Due to the specific properties, variety and complexity of natural wood, wood materials and wood composites, the machining of parts made out of these materials exhibits specific challenges. In order to further improve productivity, quality and efficiency in wood machining, innovative solutions with respect to tool technology, process planning, machinery, process monitoring and intelligent control are necessary. This keynote paper reviews and summarizes scientific developments in wood machining in recent years. Furthermore, exemplary current an ongoing research activities are introduced. Finally, the paper presents and discusses future potentials regarding new approaches for intelligent process control in wood machining.