Lithographiebasierte Fertigung keramischer Bauteile

Im Rahmen des EU-Projektes PHOCAM entwickelt das beteiligte Konsortium Anlagen und Materialien für die generative Fertigung keramischer Bauteile auf Basis der Photopolymerisation. Das Kernelement der verwendeten Fertigungsanlagen, der DLP Projektor, erzeugt mittels leistungsstarker LEDs und einem 1080p DMD (Digital Micromirror Device) Bilder mit 1920x1080 Bildpunkten und der Pixelgröße von 40µm, woraus sich die Baufeldgröße von 76,8x43,2mm ergibt. Ein hochviskoser Schlicker, bestehen aus einem gefülltem fotosensitiven Harzsystem, wird von unten durch die gläserne Materialwanne belichtet, wodurch der Schlicker lokal aushärtet (polymerisiert). Auf diese Weise entsteht der Grünling, der in schichtbauweise (Standardschichtdicke von 25-50µm) aufgebaut ist. Im nachfolgenden Sinterprozess werden die Grünlinge zu den fertigen Keramikteilen gebrannt. Als keramisches Basismaterial für den Schlicker wurde vorwiegend Aluminiumoxid in Pulverform verwendet. Mit dem entwickelten System konnten bislang Schlicker mit einem Füllgrad (Keramikanteil) bis zu 50Vol% erfolgreich verarbeitet und zu Keramikteilen mit einer theoretischen Dichte von 99,6% gesintert werden.

Untersuchung zur Reduzierung des Verzugs durch Vorwärmung bei der Herstellung von Aluminiumbauteilen mittels SLM

Das generative Fertigungsverfahren Selective Laser Melting (SLM) wird zur direkten Herstellung von metallischen Funktionsbauteilen verwendet. Während des Bauprozesses entstehen durch den schichtweisen Aufbau und die lokale Energieeinbringung mittels eines fokussierten Laserstrahls thermisch induzierte Eigenspannungen, die zu Verzug des Bauteils oder von Bauteilbereichen führen können. Üblicherweise werden die Verzüge durch Stützstrukturen zwischen Bauteil und Substratplatte verhindert. Jedoch ist es nicht immer möglich alle Bereiche eines Bauteils, je nach Komplexität der Geometrie oder Zugänglichkeit, mit Stützstrukturen zu versehen bzw. diese wieder zu entfernen. Durch eine Vorwärmung der Substratplatte während des Bauprozesses können die Verzüge reduziert oder ganz vermieden werden. Jedoch ist bisher keine systematische Untersuchung des Einflusses der Vorwärmung auf Verzüge von Aluminium Bauteilen durchgeführt worden. Ziel dieser Arbeiten ist daher die systematische Untersuchung der Auswirkung einer Vorwärmung beim SLM von Aluminiumbauteilen und die Ermittlung der geeigneten Vorwärmtemperatur, bei der nahezu keine Verzüge mehr entstehen. Eine signifikante Verzugsreduzierung im Vergleich zu den Verzügen ohne Vorwärmung zeigt sich ab einer Vorwärmtemperatur von 150°C. Bei einer Vorwärmtemperatur von 250°C sind im Rahmen der Messgenauigkeit unabhängig von der untersuchten Twincantilever Testgeometrie keine Verzüge mehr feststellbar. Neben der Reduzierung der Verzüge verhindert die Vorwärmung außerdem spannungsbedingte Risse im Bauteil, die ohne Vorwärmung zum Abreißen von Teilen der Testgeometrie führen können. Mit 90 HV 0,1 bei 250°C Vorwärmtemperatur ist die Härte größer als die geforderte Mindesthärte nach DIN EN 1706 von Druckgussbauteilen aus dem Werkstoff AlSi10Mg. Aus diesem Ergebnis kann abgeleitet werden, dass eine Vorwärmtemperatur von 250°C geeignet ist, Bauteile aus dem Werkstoff AlSi10Mg mit SLM defektfrei und prozesssicher herzustellen und Verzüge vollständig zu vermeiden.

Ansätze zur Qualitätsbewertung von generativen Fertigungsverfahren durch die Einführung eines Kennzahlensystems

Generative Fertigungsverfahren haben sich in den letzten Jahren als effektive Werkzeuge für die schnelle Entwicklung von Produkten nahezu beliebiger Komplexität entwickelt. Gleichzeitig wird gefordert, die Reproduzierbarkeit der Bauteile und auch seriennahe bzw. seriengleiche Eigenschaften zu gewährleisten. Die Vielfalt und der Umfang der Anwendungen sowie die große Anzahl verschiedener generativer Fertigungsverfahren verlangen adäquate Qualitätsüberwachungs- und Qualitätskontrollsysteme. Ein Lösungsansatz für die Qualitätsbewertung von generativen Fertigungsverfahren besteht in der Einführung eines Kennzahlensystems. Hierzu müssen zunächst Anforderungsprofile und Qualitätsmerkmale für generativ hergestellte Bauteile definiert werden, welche durch Prüfkörpergeometrien abgebildet und mit Hilfe von Einzelkennzahlen klassifiziert werden. In Rahmen der durchgeführten Untersuchungen wurde die Qualitätsbewertung anhand von Prüfkörpergeometrien am Beispiel des Laser-Sinterprozesses qualifiziert. Durch Beeinflussung der Prozessparameter, d.h. der gezielten Einbringung von Störgrößen, welche einzeln oder in Kombination zu unzulässigen Qualitätsschwankungen führen können, ist es möglich, die Qualität des Produktes zu beurteilen. Die Definition von Einzelkennzahlen, die eine Steuerung und Kontrolle sowie eine Vorhersage potentieller Fehler ermöglicht, bietet hierbei essentielle Möglichkeiten zur Qualitätsbewertung. Eine Zusammenführung zu einem gesamtheitlichen Kennzahlensystem soll zum einen den Prozess auf Grundlage der definierten Anforderungsprofile bewerten und zum anderen einen direkten Zusammenhang der ausgewählten Störgrößen und Prozessgrößen herleiten, um vorab eine Aussage über die Bauteilqualität treffen zu können.

Vergleich von additiv und herkömmlich gefertigten Strukturen für ein neuartiges Regalfahrzeug

Der Einsatz additiver Fertigungsverfahren ist in den vergangenen Jahren stark angestiegen. Technische Weiterentwicklungen der Maschinen machen den Einsatz dieser Fertigungsverfahren für Industrieanwen-dungen immer attraktiver. In einer Untersuchung am Fraunhofer-Institut für Materialfluss und Logistik IML wurden die Einsatzmöglichkeiten additiver Fertigungsverfahren im Bereich autonomer Regalfahrzeuge analysiert. Die Adaption eines neuartigen Förderfahrzeuges für den Einsatz in Regalanlagen steht hierbei im Fokus der Untersuchung. Diese Analyse stellt die Besonderheiten der additiven Fertigung heraus und vergleicht den Herstellungsprozess mit herkömmlichen Verfahren.

Repair - Beispiel: Mobile mit Halogenleuchten

Das RTeJournal möchte in seiner Rubrik:“ Repair“, Berichte aufnehmen, in denen die Reparatur oder der Ersatz von Bauteilen durch Additive Manufacturing (AM) Lösungen aufgenommen wird. Einmal als Anregung sich damit auseinander zu setzen und gleichzeitig auch als Dienstleistung beim Bedarf von Reparaturen. Es würde uns freuen, wenn Sie uns Beispiele mit einem kleinen Reparaturbericht zusenden könnten, die zum Einsatz von Additive Manufacturing führten. Email: eich@fh-aachen.de

Surface quality of profile extrusion dies manufactured by Selective Laser Melting

The design of plastics profile extrusion dies becomes increasingly more complex so that conventional manufacture processes reach their limit in the die manufacture. A feasible manufacture of arbitrarily designed dies is only possible by additive manufacturing. An especially promising process is hereby the Selective Laser Melting with which metal parts with series identical mechanical properties can be produced without the need for part specific tooling or downstream sintering processes. Disadvantegeous is, however, the relatively rough surface of additively manufactured parts. Against this background, the manufacturing of an profile extrusion die by Selective Laser Melting and the plastics profile surface quality, that can be achieved with such dies, is investigated. For this purpose, profiles are extruded both with an additively manufactured die and a conventionally milled sample of the same die geometry. In case of the additively manufactured die a concept for the surface finishing of the flow channel is required, which can be applied to arbitrarily shaped geometries. Therefore, two different reworking processes are applied only to the die land of the flow channel. The comparison of the surface roughnesses shows that the additively manufactured die with a polished die land delivers the same surface quality as the conventional die.

Analyzing PL/1 Legacy Ecosystems: An Experience Report

This paper presents a case study of analyzing a legacy PL/1 ecosystem that has grown for 40 years to support the business needs of a large banking company. In order to support the stakeholders in analyzing it we developed St1-PL/1 — a tool that parses the code for association data and computes structural metrics which it then visualizes using top-down interactive exploration. Before building the tool and after demonstrating it to stakeholders we conducted several interviews to learn about legacy ecosystem analysis requirements. We briefly introduce the tool and then present results of analysing the case study. We show that although the vision for the future is to have an ecosystem architecture in which systems are as decoupled as possible the current state of the ecosystem is still removed from this. We also present some of the lessons learned during our experience discussions with stakeholders which include their interests in automatically assessing the quality of the legacy code.

Matrix models for quantifying competitive intransitivity from species abundance data

In a network of competing species, a competitive intransitivity occurs when the ranking of competitive abilities does not follow a linear hierarchy (A > B > C but C > A). A variety of mathematical models suggests that intransitive networks can prevent or slow down competitive exclusion and maintain biodiversity by enhancing species coexistence. However, it has been difficult to assess empirically the relative importance of intransitive competition because a large number of pairwise species competition experiments are needed to construct a competition matrix that is used to parameterize existing models. Here we introduce a statistical framework for evaluating the contribution of intransitivity to community structure using species abundance matrices that are commonly generated from replicated sampling of species assemblages. We provide metrics and analytical methods for using abundance matrices to estimate species competition and patch transition matrices by using reverse-engineering and a colonization-competition model. These matrices provide complementary metrics to estimate the degree of intransitivity in the competition network of the sampled communities. Benchmark tests reveal that the proposed methods could successfully detect intransitive competition networks, even in the absence of direct measures of pairwise competitive strength. To illustrate the approach, we analyzed patterns of abundance and biomass of five species of necrophagous Diptera and eight species of their hymenopteran parasitoids that co-occur in beech forests in Germany. We found evidence for a strong competitive hierarchy within communities of flies and parasitoids. However, for parasitoids, there was a tendency towards increasing intransitivity in higher weight classes, which represented larger resource patches. These tests provide novel methods for empirically estimating the degree of intransitivity in competitive networks from observational datasets. They can be applied to experimental measures of pairwise species interactions, as well as to spatio-temporal samples of assemblages in homogenous environments or environmental gradients.

Mining frequent bug-fix code changes

Detecting bugs as early as possible plays an important role in ensuring software quality before shipping. We argue that mining previous bug fixes can produce good knowledge about why bugs happen and how they are fixed. In this paper, we mine the change history of 717 open source projects to extract bug-fix patterns. We also manually inspect many of the bugs we found to get insights into the contexts and reasons behind those bugs. For instance, we found out that missing null checks and missing initializations are very recurrent and we believe that they can be automatically detected and fixed.

Improvement of Mechanical Properties and Life Extension of High Reliability Structural Components by Laser Shock Processing

Profiting by the increasing availability of laser sources delivering intensities above 109 W/cm2 with pulse energies in the range of several Joules and pulse widths in the range of nanoseconds, laser shock processing (LSP) is being consolidating as an effective technology for the improvement of surface mechanical and corrosion resistance properties of metals and is being developed as a practical process amenable to production engineering. The main acknowledged advantage of the laser shock processing technique consists on its capability of inducing a relatively deep compression residual stresses field into metallic alloy pieces allowing an improved mechanical behaviour, explicitly, the life improvement of the treated specimens against wear, crack growth and stress corrosion cracking. Following a short description of the theoretical/computational and experimental methods developed by the authors for the predictive assessment and experimental implementation of LSP treatments, experimental results on the residual stress profiles and associated surface properties modification successfully reached in typical materials (specifically Al and Ti alloys) under different LSP irradiation conditions are presented. In particular, the analysis of the residual stress profiles obtained under different irradiation parameters and the evaluation of the corresponding induced surface properties as roughness and wear resistance are presented.

Programmed design of ship forms

This paper describes a new category of CAD applications devoted to the definition and parameterization of hull forms, called programmed design. Programmed design relies on two prerequisites. The first one is a product model with a variety of types large enough to face the modeling of any type of ship. The second one is a design language dedicated to create the product model. The main purpose of the language is to publish the modeling algorithms of the application in the designer knowledge domain to let the designer create parametric model scripts. The programmed design is an evolution of the parametric design but it is not just parametric design. It is a tool to create parametric design tools. It provides a methodology to extract the design knowledge by abstracting a design experience in order to store and reuse it. Programmed design is related with the organizational and architectural aspects of the CAD applications but not with the development of modeling algorithms. It is built on top and relies on existing algorithms provided by a comprehensive product model. Programmed design can be useful to develop new applications, to support the evolution of existing applications or even to integrate different types of application in a single one. A three-level software architecture is proposed to make the implementation of the programmed design easier. These levels are the conceptual level based on the design language, the mathematical level based on the geometric formulation of the product model and the visual level based on the polyhedral representation of the model as required by the graphic card. Finally, some scenarios of the use of programmed design are discussed. For instance, the development of specialized parametric hull form generators for a ship type or a family of ships or the creation of palettes of hull form components to be used as parametric design patterns. Also two new processes of reverse engineering which can considerably improve the application have been detected: the creation of the mathematical level from the visual level and the creation of the conceptual level from the mathematical level. © 2012 Elsevier Ltd. All rights reserved. 1. Introduction

Dynamic binary translation using run-time feedbacks

Dynamic binary translation is the process of translating, modifying and rewriting executable (binary) code from one machine to another at run-time. This process of low-level re-engineering consists of a reverse engineering phase followed by a forward engineering phase. UQDBT, the University of Queensland Dynamic Binary Translator, is a machine-adaptable translator. Adaptability is provided through the specification of properties of machines and their instruction sets, allowing the support of different pairs of source and target machines. Most binary translators are closely bound to a pair of machines, making analyses and code hard to reuse. Like most virtual machines, UQDBT performs generic optimizations that apply to a variety of machines. Frequently executed code is translated to native code by the use of edge weight instrumentation, which makes UQDBT converge more quickly than systems based on instruction speculation. In this paper, we describe the architecture and run-time feedback optimizations performed by the UQDBT system, and provide results obtained in the x86 and SPARC® platforms.

Developing relational navigation to effectively understand software

Effective comprehension of complex software systems requires understanding of both the individual documents that represent software and the complex relationships that exist within and between documents. Relationships of all kinds play a vital role in a software engineer's comprehension of, and navigation within and between, software documents. User-determined relationships have the additional role of enabling the engineer to create and maintain relational documentation that cannot be generated by tools or derived from other relationships. We argue that for a software development environment to effectively support the understanding of complex software systems, relational navigation must be supported at both the document-focused (intra-document) and relation-focused (inter-document) levels. The need for a relation-focused approach is highlighted by an evaluation of an existing document-focused relational interface. We conclude with the requirements for a relation-focused approach to relational navigation. These requirements focus on the user's perspective when interacting with a collection of related documents. We define the requirements for a software development environment that effectively supports the understanding of the software documents and relationships that define a complex software system.

Green operations initiatives in the automotive industry:an environmental reports analysis and benchmarking study

Purpose: The purpose of this paper is to focus on investigating and benchmarking green operations initiatives in the automotive industry documented in the environmental reports of selected companies. The investigation roadmaps the main environmental initiatives taken by the world's three major car manufacturers and benchmarks them against each other. The categorisation of green operations initiatives that is provided in the paper can also help companies in other sectors to evaluate their green practices. Design/methodology/approach: The first part of the paper is based on existing literature on the topic of green and sustainable operations and the "unsustainable" context of automotive production. The second part relates to the roadmap and benchmarking of green operations initiatives based on an analysis of secondary data from the automotive industry. Findings: The findings show that the world's three major car manufacturers are pursuing various environmental initiatives involving the following green operations practices: green buildings, eco-design, green supply chains, green manufacturing, reverse logistics and innovation. Research limitations/implications: The limitations of this paper start from its selection of the companies, which was made using production volume and country of origin as the principal criteria. There is ample evidence that other, smaller, companies are pursuing more sophisticated and original environmental initiatives. Also, there might be a gap between what companies say they do in their environmental reports and what they actually do. Practical implications: This paper helps practitioners in the automotive industry to benchmark themselves against the major volume manufacturers in three different continents. Practitioners from other industries will also find it valuable to discover how the automotive industry is pursuing environmental initiatives beyond manufacturing, apart from the green operations practices covering broadly all the activities of operations function. Originality/value: The originality of the paper is in its up-to-date analysis of environmental reports of automotive companies. The paper offers value for researchers and practitioners due to its contribution to the green operations literature. For instance, the inclusion of green buildings as part of green operations practices has so far been neglected by most researchers and authors in the field of green and sustainable operations. © Emerald Group Publishing Limited.

Using a systems approach in logistics design and planning

The international economic and business environment continues to develop at a rapid rate. Increasing interactions between economies, particularly between Europe and Asia, has raised many important issues regarding transport infrastructure, logistics and broader supply chain management. The potential exists to further stimulate trade provided that these issues are addressed in a logical and systematic manner. However, if this potential is to be realised in practice there is a need to re-evaluate current supply chain configurations. A mismatch currently exists between the technological capability and the supply chain or logistical reality. This mismatch has sharpened the focus on the need for robust approaches to supply chain re-engineering. Traditional approaches to business re-engineering have been based on manufacturing systems engineering and business process management. A recognition that all companies exist as part of bigger supply chains has fundamentally changed the focus of re-engineering. Inefficiencies anywhere in a supply chain result in the chain as a whole being unable to reach its true competitive potential. This reality, combined with the potentially radical impact on business and supply chain architectures of the technologies associated with electronic business, requires organisations to adopt innovative approaches to supply chain analysis and re-design. This paper introduces a systems approach to supply chain re-engineering which is aimed at addressing the challenges which the evolving business environment brings with it. The approach, which is based on work with a variety of both conventional and electronic supply chains, comprises underpinning principles, a methodology and guidelines on good working practice, as well as a suite of tools and techniques. The adoption of approaches such as that outlined in this paper helps to ensure that robust supply chains are designed and implemented in practice. This facilitates an integrated approach, with involvement of all key stakeholders throughout the design process.