Marvin Binder

An advanced numerical approach on tool wear simulation for tool and process design in metal cutting

Abstract Tool wear is an important criterion in metal cutting affecting part quality, chip formation and the economics of the cutting process. In order to account for tool wear adequately in tool and process design, simulation tools predicting tool wear in metal cutting processes are required. Within this paper, an advanced simulation approach is presented, coupling FE simulations of chip formation with a user-defined subroutine which extends the functionalities of the commercial FE code for wear simulation laying the focus on the development of this method. The continuous process of wearing is discretized in finite steps and the wear rate is modelled to be constant between. Based on the Usui wear rate equation, the local thermo-mechanical load obtained by FE simulation is transformed into local wear rates. The geometric representation of the wear progress is implemented via shifting of the finite element nodes of the engaged tool domain. A novel iterative procedure of updating the tool geometry in order to account for the wear progress is presented.

Ecological evaluation of consumptions in manufacturing within the automotive sector

Nowadays the necessity to improve the transparency of consumptions origins of electrical energy as well as auxiliary materials (e.g., lubricoolants, pressurised air, etc.) in the industrial manufacturing environment is increasing more than ever. Methodologies for measuring, predicting and estimating consumptions are being developed in order to assess the environmental impacts during the production. This paper presents a detailed analysis of all energy and material flows for the manufacturing of two different demonstrator products using a bottom-up measurement approach. In order to identify potential savings and to reduce the complexity of the data gathering, an assessment of the main origins of consumptions on the one hand as well as the most resource intensive process inputs on the other hand has been conducted. Based on the initial technology chain and its evaluation, an alternative technology chain with several changes in the processes has been investigated in order to reveal potential savings and demo...

Life Cycle Based Evaluation and Interpretation of Technology Chains in Manufacturing

This chapter describes a methodology to gather, assess and interpret the ecological impact of technology chains within industrial manufacturing. The explained methodology leads to significant information about high consuming processes and important energy and material flows. Industrial companies cannot allocate the exact consumptions in the manufacturing processes. Especially costs and consumptions for media like compressed air or centrally provided lubricants are mostly distributed by means of the number of machines rather than by actual consumption figures. By utilising the presented methodology not only information about real consumptions, but furthermore ecological data can be generated for various purposes such as ecological product declarations and evaluation of alternative production chains. The methodology is exemplarily applied in two industrial case studies and results of these studies are shown in this chapter.

Ecological Assessment of Coated Cemented Carbide Tools and Their Behavior during Machining

In the last years and even decades the research on ecological evaluation models has grown. Both procedures for entire companies or plants as well as methods for describing single processes have been developed. Therefore the demand for process oriented approaches which can be aggregated into considerations of higher levels is prevailing.

The Ecological Footprint on Product Level in Machining – From the Conceptional Methodology to the Industrial Application

In line with the striving for a more sustainable orientation in manufacturing systems and industrial pursuit of resource efficiency, companies are looking for efficient processes. The consumption of electrical energy and other resources during the manufacturing phase is considered by the ecological footprint. This study offers a conception for the determination of the ecological footprint within manufacturing systems based on life cycle assessments. The existence of basic data is a requirement for such an evaluation. Therefore, a holistic measurement system is presented which is adaptable to small as well as large scaled production environments and different usage scenarios, e.g. full scale measurement or detailed process analysis.