Kaiserslautern - Fachbereich Maschinenbau und Verfahrenstechnik
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Micro machining with micro pencil grinding tools (MPGTs) is an emerging technology that can be used to manufacture closed microchannel structures in hard and brittle materials as well as hardened steels like 16MnCr5. At their current operating conditions, these tools have a comparatively short tool life. In previous works, MPGTs in combination with a minimum quantity lubrication (MQL) system were used to manufacture microchannels in 16MnCr5 hardened steel. The study has shown that steel adhesions clog the abrasive layer of MPGTs, most likely resulting from insufficient lubrication. In this paper, a metalworking fluid (MWF) supply method was developed to improve the process: a submerged micro grinding process, in which machining takes place inside a pool of MWF. In this study, the effect of seven types of MWFs on material adhesions at the bottom surface of the tool is evaluated. Equivalent good MWFs are then compared in a micro pendulum grinding experiment till failure.
In selective laser melting (SLM) the variation of process parameters significantly impacts the resulting workpiece characteristics. In this study, AISI 316L was manufactured by SLM with varying laser power, layer thickness, and hatch spacing. Contrary to most studies, the input energy density was kept constant for all variations by adjusting the scanning speed. The varied parameters were evaluated at two different input energy densities. The investigations reveal that a constant energy density with varying laser parameters results into considerable differences of the workpieces’ roughness, density, and microhardness. The density and the microhardness of the manufactured components can be improved by selecting appropriate parameters of the laser power, the layer thickness, and the hatch spacing. For this reason, the input energy density alone is no indicator for the resulting workpiece characteristics, but rather the ratio of scanning speed, layer thickness, or hatch spacing to laser power. Furthermore, it was found that the microhardness of an additively manufactured material correlates with its relative density. In the parameter study presented in this paper, relative densities of the additively manufactured workpieces of up to 99.9% were achieved.
During cryogenic turning of metastable austenitic stainless steels, a deformation-induced phase transformation from γ-austenite to α’-martensite can be realized in the workpiece subsurface, which results in a higher microhardness as well as in improved fatigue strength and wear resistance. The α’-martensite content and resulting workpiece properties strongly depend on the process parameters and the resulting thermomechanical load during cryogenic turning. In order to achieve specific workpiece properties, extensive knowledge about this correlation is required. Parametric models, based on physical correlations, are only partly able to predict the resulting properties due to limited knowledge on the complex interactions between stress, strain, temperature, and the resulting kinematics of deformation-induced phase transformation. Machine learning algorithms can be used to detect this kind of knowledge in data sets. Therefore, the goal of this paper is to evaluate and compare the applicability of three machine learning methods (support vector regression, random forest regression, and artificial neural network) to derive models that support the prediction of workpiece properties based on thermomechanical loads. For this purpose, workpiece property data and respective process forces and temperatures are used as training and testing data. After training the models with 55 data samples, the support vector regression model showed the highest prediction accuracy.
Within this work, we utilize the framework of phase field modeling for fracture in order to handle a very crucial issue in terms of designing technical structures, namely the phenomenon of fatigue crack growth. So far, phase field fracture models were applied to a number of problems in the field of fracture mechanics and were proven to yield reliable results even for complex crack problems. For crack growth due to cyclic fatigue, our basic approach considers an additional energy contribution entering the regularized energy density function accounting for crack driving forces associated with fatigue damage. With other words, the crack surface energy is not solely in competition with the time-dependent elastic strain energy but also with a contribution consisting of accumulated energies, which enables crack extension even for small maximum loads. The load time function applied to a certain structure has an essential effect on its fatigue life. Besides the pure magnitude of a certain load cycle, it is highly decisive at which point of the fatigue life a certain load cycle is applied. Furthermore, the level of the mean load has a significant effect. We show that the model developed within this study is able to predict realistic fatigue crack growth behavior in terms of accurate growth rates and also to account for mean stress effects and different stress ratios. These are important properties that must be treated accurately in order to yield an accurate model for arbitrary load sequences, where various amplitude loading occurs.
Modeling of solid-particle effects on bubble breakage and coalescence in slurry bubble columns
(2020)
Solid particles heavily affect the hydrodynamics in slurry bubble columns. The effects arise through varying breakup and coalescence behavior of the bubbles with the presence of solid particles where particles in the micrometer range lead to a promotion of coalescence in particular. To simulate the gas-liquid-solid flow in a slurry bubble column, the Eulerian multifluid approach can be employed to couple computational fluid dynamics (CFD) with the population balance equation (PBE) and thus to account for breakup and coalescence of bubbles.
In this work, three approaches are presented to modify the breakup and coalescence models to account for enhanced coalescence in the coupled CFD-PBE framework. The approaches are applied to a reference simulation case with available experimental data. In addition, the impacts of the modifications on the simulated bubble size distribution (BSD) and the applicability of the approaches are evaluated. The capabilities as well as the differences and limits of the approaches are demonstrated and explained.
In the field of metal additive manufacturing (AM), one of the most used methods is selective laser melting (SLM)—building components layer by layer in a powder bed via laser. The process of SLM is defined by several parameters like laser power, laser scanning speed, hatch spacing, or layer thickness. The manufacturing of small components via AM is very difficult as it sets high demands on the powder to be used and on the SLM process in general. Hence, SLM with subsequent micromilling is a suitable method for the production of microstructured, additively manufactured components. One application for this kind of components is microstructured implants which are typically unique and therefore well suited for additive manufacturing. In order to enable the micromachining of additively manufactured materials, the influence of the special properties of the additive manufactured material on micromilling processes needs to be investigated. In this research, a detailed characterization of additive manufactured workpieces made of AISI 316L is shown. Further, the impact of the process parameters and the build-up direction defined during SLM on the workpiece properties is investigated. The resulting impact of the workpiece properties on micromilling is analyzed and rated on the basis of process forces, burr formation, surface roughness, and tool wear. Significant differences in the results of micromilling were found depending on the geometry of the melt paths generated during SLM.
When machining metastable austenitic stainless steel with cryogenic cooling, a deformation-induced phase transformation from γ-austenite to α′-martensite can be realized in the workpiece subsurface. This leads to a higher microhardness and thus improved fatigue and wear resistance. A parametric and a non-parametric model were developed in order to investigate the correlation between the thermomechanical load in the workpiece subsurface and the resulting α′-martensite content. It was demonstrated that increasing passive forces and cutting forces promoted the deformation-induced phase transformation, while increasing temperatures had an inhibiting effect. The feed force had no significant influence on the α′-martensite content. With the proposed models it is now possible to estimate the α′-martensite content during cryogenic turning by means of in-situ measurement of process forces and temperatures.
The application of plant suspension culture to produce valuable compounds, such as the triterpenoids oleanolic acid and ursolic acid, is a well-established alternative to the cultivation of whole plants. Cambial meristematic cells (CMCs) are a growing field of research, often showing superior cultivation properties compared to their dedifferentiated cell (DDC) counterparts. In this work, the first-time establishment of O. basilicum CMCs is demonstrated. DDCs and CMCs were cultivated in shake flasks and wave-mixed disposable bioreactors (wDBRs) and evaluated regarding triterpenoid productivity and biomass accumulation. CMCs showed characteristic small vacuoles and were found to be significantly smaller than DDCs. Productivities of oleanolic and ursolic acid of CMCs were determined at 3.02 ± 0.76 mg/(l*d) and 4.79 ± 0.48 mg/(l*d) after 19 days wDBR cultivation, respectively. These values were consistently higher than any productivities determined for DDCs over the observed cultivation period of 37 days. Elicitation with methyl jasmonate of DDCs and CMCs in shake flasks resulted in increased product contents up to 48 h after elicitor addition, with the highest increase found in CMCs at 232.30 ± 19.33% (oleanolic acid) and 192.44 ± 18.23% (ursolic acid) after 48 h.
Dort, wo in Prozessen und Anwendungen Flüssigkeiten unter hohem Druck in rotierende Systeme eingespeist werden, kommen Radialwellendichtringe an die Grenzen ihrer Leistungsfähigkeit. Treten in den Dichtkontakten zusätzlich noch hohe Relativgeschwindigkeiten auf, eignen sich auch Gleitringdichtungen nicht mehr als dynamische Dichtung. Aufgrund ihrer sehr hohen thermischen Beständigkeit etablierten sich Rechteckdichtringe aus Hochleistungskunststoffen wie Polyimiden für diese Anwendungen. In ihrem Aufbau ähneln sie Kolbenringen, wie sie in Verbrennungskraftmaschinen und Kolbenmaschinen zum Einsatz kommen, weshalb im englischen Sprachgebrauch die Bezeichnung „piston ring“ verbreitet ist.
Als zentrale Größe für die Belastung des Rechteckdichtrings wird das Lastäquivalent aus dem Produkt von anliegendem Fluiddruck und der Relativgeschwindigkeit im Kontakt herangezogen (auch p · v-Wert). Der p · v-Wert wird als Systemkenngröße herangezogen, um die Eignung des Werkstoffs hinsichtlich ertragbarer Reibleistungen im Kontakt für die jeweilige Anwendung zu prüfen. Vorangegangene Arbeiten befassten sich vorwiegend mit der Leckagebildung, Reibungsreduzierung sowie der Bestimmung geeigneter Materialpaarungen für das Dichtsystem. Dabei wurden Einflüsse von Lageabweichungen auf die Funktionalität der Dichtringe nicht betrachtet. Mit Hilfe eines adaptierten Prüfstands am Lehrstuhl für Maschinenelemente und Getriebetechnik der Technische Universität Kaiserslautern, der zur Untersuchung von Radialwellendichtringen unter statischen und dynamischen Auslenkungen dient, soll das Verständnis über Rechteckdichtringe unter statischen und dynamischen Auslenkung erweitert werden.
Das Verhalten von Rechteckdichtringen unter statischen und dynamischen Lageabweichungen wird von sich überlagernden Einflüssen bestimmt. Hierbei hängt die auftretende Leckage des Dichtsystems vorrangig von den Betriebsgrößen wie Fluiddruck und den statischen Lageabweichungen ab. Dynamische Verlagerungen innerhalb des Dichtsystem beeinflussen das Leckageverhalten negativ, wobei kein Zusammenhang zwischen Leckage und Betrag oder Frequenz der Auslenkung herrscht. Die Querschnittsfläche des Dichtrings sowie die Geometrie der Nut führen so divergierenden Betriebsverhalten, wobei die druckabhängige Leckagebildung von anderen Verhaltensmustern überlagert werden kann.
In this thesis, material removal mechanisms in grinding are investigated considering a gritworkpiece interaction as well as a grinding-wheel workpiece interaction. In grit-workpiece interaction in a micrometer scale, single grit scratch experiments were performed to investigate material removal mechanism in grinding namely rubbing, plowing, and cutting. Experiments performed were analyzed based on material removal, process forces and specific energy. A finite element model is developed to simulate a single-grit scratch process. As part of the development of the finite element scratch model a 2D and 3D model is developed. A 2D model is utilized to test
material parameters and test various mesh discretizational approaches. A 3D model undertaking the tested material parameters from the 2D model is developed and is tested against experimental results for various mesh discretization. The simulation model is validated based on process forces and ground topography from experiments. The model is also further scaled to simulate multiple grit-workpiece interaction validated against experimental results. As a final step, simulation models are developed to simulate material removal, due to the interaction of grinding wheel and workpiece. A developed virtual grinding wheel topographical model is employed to display
an approach, to upscale a grinding process from grit-workpiece interaction to wheel-workpiece
interaction. In conclusion, practical conclusions drawn and scope for future studies are derived
based on the developed simulation models.