Integrated Process Simulation of Powder Metallurgical Shaping and Sintering Applied to the Optimization of Porcelain Tile Manufacturing

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Prof. Dr.-Ing. Maksym Dosta (TU Hamburg)

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Dr.-Ing. Rolf Janßen (TU Hamburg-Harburg)

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Prof. Dr. Agenor de Noni Jr (UFSC)

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Manufacturing system models for Industry 4.0 based on highly heterogeneous and unstructured data sets

Motivation

Industry 4.0 is a concept for production that meets the requirements of a modern production system, such as flexibility or batch size 1, through a high degree of networking between machines, products and people. A prerequisite for networking is the Digital Twin. In the context of production, the Digital Twin is a digital image of a real production system, which monitors and analyzes the production system and forecasts the behavior of a production system. In this context, the Digital Twin can be based on either physics-based or data-driven models. Both types of models offer individual advantages and complement each other.

Objective

The focus of the research project is to investigate the mutual effects of physics-based and data-based modeling capabilities of production systems. To this end, a framework is being designed that combines the two types of models in a digital twin. Together with a Brazilian research group, this framework will be developed collaboratively.

Approach

To do this, a use case must first be defined that has a high degree of digitization and thus also a digital twin. Requirements for a digital twin can then be derived from this. Then, existing physics-based and data-driven modeling techniques are analyzed and a concept is explored that combines the two types of modeling. At the end, the concept is validated with the help of the use case.

Prof. Dr.-Ing. Jan C. Aurich (TU Kaiserslautern)

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Prof. Dr. Rubens M. do Nascimento (UFRN)

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A meta-learning approach to select appropriate prognostic methods for the predictive maintenance of digital manufacturing systems

Motivation

An important task of maintenance is to ensure the technical availability of machines and plants as cost efficient as possible. Predictive maintenance approaches pursue this objective by predicting potential failures of technical components and avoiding them by taking appropriate measures in advance. The forecast models used for this purpose are usually developed for a specific application and cannot be generalized.

Objective

The objective of the project is to develop a meta-learning system that allows an automated selection of the best suitable forecasting method. The results of the forecasts will eventually be used for an integrated production and maintenance planning. In addition, a monitoring and adaptation procedure is to be implemented to trigger a dynamic adaptation of the system to new system states. In this way, fore-casting methods can be selected dynamically and optimal maintenance decisions can be derived based on the current state of a production system.

Approach

The first step is to define relevant use cases for the predictive maintenance of production systems. On this basis, a framework will be developed that includes a set of forecasting methods, a methodology for integrated production and maintenance planning, and an ontology for translating information from different data sources. On this basis, the metalearning system will be designed. For this purpose, the framework will be combined with a machine learning technique for selecting and configuring forecast methods, with a simulation model and a service-oriented architecture for data acquisition and data transfer. This will be followed by the addition of a monitoring and adjustment procedure. Finally, the performance of the system is evaluated with regard to forecast errors and key production logistics figures within simulations of real industrial applications.

Prof. Dr.-Ing. Michael Freitag (University of Bremen)

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Prof. Dr.-Ing. Enzo M. Frazzon (UFSC)

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Metrologically interpretable machine learned features using latent spaces of Generative Deep Learning Models

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Prof. Dr.-Ing. Robert Schmitt (RWTH)

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Prof. Dr.-Ing. Armando Albertazzi Concalves Junior (UFSC)

Optical wireless systems with MIMO architecture in an industrial environment

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Prof. Dr. Ronald Freund (Fraunhofer HHI)

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Prof. Dr. Marcelo Eduardo Vieira Segatto (UFES)

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An adaptive simulation-based optimisation approach for the scheduling and control of dynamic manufacturing systems

Motivation

The planning and control of production processes has a significant influence on the performance of a job shop manufacturing system. The production is subject to dynamic influences (e.g. faults caused by machine failures or rush orders), which have to be considered for the production planning and control. Common methods are therefore normally divided into modules for calculating plans and modules for operational control. In general, optimisation only takes place at the strategic planning level, while detailed planning is carried out on the basis of simple, static dispatching rules. This allows the generation of schedules in short computation times, but generally no optimal schedules based on the current state of the production system are generated.

Approach of the 1st phase

This Brazilian-German cooperation project aims at developing a simulation-based optimisation method for the scheduling and control of dynamic job shop manufacturing systems. The traditional approach of simulation-based optimisation is suitable for solving complex, stochastic scheduling problems. Within the project, this approach will be extended to additionally incorporate the dynamics of job shops, so that scheduling decisions and the configuration of the shop floor control can be optimized with respect to the current system state.

Results of the 1st phase

In the first phase of the project, a simulation-based optimisation method for controlling dynamic job shop production has been developed. The classical approach of simulation-based optimisation was extended in such a way that the dynamics of job shop manufacturing are taken into account and the optimisation of planning decisions and control rules is always based on the current system state. In order to gain this system state from the physical production process, an automated method to exchange data between a manufacturing execution system and the simulation model within the optimisation approach was developed. The developed method was evaluated considering the job shop production of a Brazilian producer of mechanical parts.

Objectives of the 2nd phase

In the second project phase, a method for the integrated control of inventory, production and maintenance processes has to be developed in order to map the current status of a production system in more detail. This means that maintenance orders can be scheduled for the machines in addition to the existing method and the inventory stocks can be taken into account for planning and control.

Approach of the 2nd phase

Initially, methods for planning maintenance jobs (Germany) and methods for inventory control (Brazil) using up-to-date system data will be developed in parallel. Subsequently, both approaches will be combined to an integrated inventory, production and maintenance control method, which will then be evaluated in a real scenario using data from the industry partner Rudolph Usinados as well as by scenarios from the literature.

Prof. Dr.-Ing. Michael Freitag (University of Bremen)

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Prof. Dr.-Ing. Enzo M. Frazzon (UFSC)

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Energy efficient manufacturing chain for advanced bainitic forging steels based on thermo-mechanical processing

The forging sector for the automotive industry nowadays seeks for more resource efficient processes. In order to reduce energy consumption with a possibility of significant cost reduction, this project aims at developing innovative process chains for new generation bainitic steels with continuous direct cooling after forging (figure a), replacing the traditional hardening and tempering processes.

Two different commercial available new generation bainitic steels with low and high Silicon content and additionally a steel with higher carbon content which will be developed by the Spray Forming process will be employed. Extensive physical and FEM-simulation and instrumented forging experimentation will allow the determination of the processing windows for these steels. In process and in situ techniques (figure b) will be used to gain information about the phase transformation kinetics by means of a special developed eddy-current sensor in specific experiments. Different thermo-mechanical processes will be developed, including the forging at different temperatures in the hot and warm range, controlled cooling with different rates and cold calibration. The forged samples will be characterized concerning the final microstructure and mechanical properties. As mechanical parts also need to accomplish with good surface properties concerning improved wear and fatigue resistance, different surface treatments after forging will be applied and evaluated, as induction hardening, low temperature plasma nitriding and deep rolling. With well-defined microstructures, excellent properties are expected to be obtained with similar mechanical properties to those obtained by the traditional quenching and tempering or even higher strengths and superior ductility.

Prof. Dr.-Ing. H.-W. Zoch (IWT Bremen)

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Prof. Dr. Alexandre da Silva Rocha (UFRGS)

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Manufacturing of ceramic membranes for oil-in-water emulsification and oil recovery from wastewater (Phase 1)

Emulsions play an important role in product development and formulation, as well as encapsulation of food, pharmaceutical and cosmetic products. Conventional methods for emulsion production and/or separation present some drawbacks, such as the use of high shear stress, high energy demanding and polydisperse droplet size distribution. In this sense, membrane technology emerges as an alternative method to overcome these issues and to produce fine and stable emulsions. Most of the research is focused on polymeric membranes. However, membrane performance still needs developments towards scaling up, mainly regarding fouling behavior.

Ceramic membranes arise as effective options for oily wastewater treatment or emulsification, since they exhibit superior resistance to high temperature, high concentration of oil content, foulants, and strong cleaning agents. On the other hand, commercial available ceramic filtration membranes do often have a broad pore size distribution, which lead to inhomogeneous droplet sizes during emulsification. Therefore, new manufacturing techniques still need to be developed for producing membranes that show narrow pore size distribution in the range of 0,1-1 µm and reduced fouling, and consequently increasing membrane lifetime and economic feasibility.

The novelty of this project is the manufacturing of polymer derived ceramic membranes at the University of Bremen, whose properties can be altered on the nanoscale (composition of the precursor) and by the processing technique (shaping, pyrolysis temperature). Two different precursors, polysiloxanes and a polysilazane, will be studied as precursor, mixed with filler particles and template particles and casted or pressed to membranes. Beside the preparation of a defined macropore structure, the surface characteristic will be altered between hydrophilic and hydrophobic by varying materials compositions and the use of different pyrolysis temperatures. At the University of Santa Catarina the manufacturing of oxidic ceramic membranes (ZrO2, Al2O3) with uniform pore size distribution by tape casting will be included for comparison reason. The surface characteristic of these membranes will be adjusted by grafting silanes of different polarity. The influence of the pore size distribution and the surface characteristic on the emulsification as well as oil recovery from aqueous wastewater and a first scale-up of membrane geometries will be investigated.

Dr. Michaela Wilhelm (Uni Bremen)

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Prof. Dr.-Ing. Dachamir Hotza (UFSC)

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Evaluation of sheet metal covers to improve tool life in forging (Phase 3)

Years ago in metal cutting industry the revolutionary substitution of monolithic cutting tools by tool-holders combined with small and easy to exchange indexable cutting inserts opened completely new possibilities for process and material efficiency, accuracy, and tool design. In closed-die forging the tooling costs make up a significant part of the total component costs. As not only the abrasive and adhesive wear but also the temperature cycle, which results in thermal fatigue, is only present in the thin surface layer of the tool, the application of an inexpensive and easy to exchange sheet metal cover, which well fits the engraving of the die, could result in a benefit, although extra effort is needed.

First works show in numerical simulations of closed-die forging a reduction of the thermo shock on the surface of the die and in total a reduction of the maximal surface temperature of about 140 K, when using a sheet metal cover. Furthermore a reduction of the abrasive wear could be estimated. In addition, the simulation showed, that particularly at tight inner radii, which can be increased by the thickness of the sheet when the die cover is used, a reduction of the notch effect can be seen, which leads to doubling of the expected number of forging cycles. First experiments showed general feasibility, although folding was observed, because of a too weak sheet material.

Thus, in the first funding period of this research project the basic mechanisms and possible applications of this concept should be investigated. Basic geometries will be studied by numerical modelling and experiments.

Materials shall be selected and characterized concerning their application for the concept in numerical simulations. For that purpose, especially the heat transfer coefficients and friction coefficients between workpiece, sheet metal cover and die have to be evaluated. In numerical simulation studies those die engraving geometries can be identified, which allow also for loosely placed die cover sheets only little tangential displacement. Concerning to these simulations, forging experiments with promising as well as critical simple die geometries will be performed. It will be analyzed weather the die covers will remain inside the engraving and if the forming is adequately possible. Furthermore it should be deducted, which suitable and easy to produce sheet preform geometries possibly can be produced by the die engraving itself.

In an eventual continuation period, the transfer to more complex and industrially relevant geometries and an analysis of the wear reduction will be studied also in experiment.

Professor Dr.-Ing. Gerhard Hirt (RWTH-Aachen)

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Prof. Dr. Ing. Lirio Schaeffer (UFRGS)

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Non-Destructive Impact Damage Detection on Carbon Fiber Reinforced Plastics

The reduction of weight of products using lightweight carbon-fiber-reinforced plastics (CFRP) is an enabler for the industry to save energy and face the international climate objectives and increasing energy costs. CFRP are characterized by a high specific stiffness and strength, which make them ideal for lightweight applications in e.g. aviation industry (airplanes, helicopters), wind turbines (rotor blades), automotive industry and even consumer goods industry (e.g. bicycles, tennis rackets etc.). In fact, new electric vehicles have been introduced recently considering a significant amount of CFRP in the support structure, thus reducing weight and enhancing driving dynamics. The demand of CFRP is expected to grow in the coming years, since the use of CFRP expands from small batch production to mass production.

The economic feasibility of CFRP products must be assured throughout the whole product life cycle. Therefore, the long term operational reliability and economic repair processes must be assured. The established concepts from aircraft and aerospace industry base upon manual processes and in general demand a replacement of damaged parts. A mass production of CFRP products requires economically feasible and efficient repair processes. Therefore, non-destructive, reliable, efficient and automated measurement technology is required to fit the material, component and repair workshop specific requirements. The development of portable and non-destructive testing methods, which reliably and holistically detect defects (CT-like), is inevitable.

Thermography is well suited for the non-destructive detection of defects in CFRP. Thermography systems are portable, cover large areas and are time efficient. The thermography is based on 2D images. These images contain an overlay of the different layers of the sample (depth information). However, the absolute position and size of the defect on the component and its depth information are not directly accessible. The objective of this project is to design, develop and setup a system to reliably detect impact damages with their respective properties (size, shape, position and depth) in CFRP components that enables a reliable repair process in the workshop environment. This goal will be achieved by enhancing the thermography to detect those 3D properties of defects in carbon fiber-reinforced plastics (CFRP). Relevant CFRP samples with different impact defects will be studied with thermography and CT. From the CT results, a defect classification will be drawn, considering properties like the depth and geometry of the defects and the severity of the damage. By fusing results from both measuring techniques, an evaluation model will be created. The model will be integrated into a demonstrator and validated. The additional benefits from this project are measurement strategies for thermography and CT to better quantify the CFRP damages. The results will improve the quality assurance of CFRP and will enable reliable repair processes. The model can be extended to other materials and defects.

Prof. Dr.-Ing. Robert Schmitt (RWTH Aachen)

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Prof. Dr. Eng. Armando Albertazzi Gonçalves Jr (UFSC)

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Development of Learnstruments for ensuring the transition of Brazilian and German manufacturing companies to Industry 4.0

German and Brazilian manufacturing companies have a long collaboration tradition with strongly linked value creation networks. In order to ensure their competitiveness in an increasing globalization, the horizontal integration of their production chains has to continuously adapt to new innovations. The industrial value creation in Germany is currently shaped by the development towards the fourth stage of industrialization, the so-called Industry 4.0. The disruptive innovations towards an Industry 4.0 are having a substantial influence on the manufacturing industry by establishing an interplay of smart factories, smart products and smart services embedded in an internet of things and services also called industrial internet. In order to enable the advantages of Industry 4.0 for the German-Brazilian value creation networks, the application of the new technologies of Industry 4.0 has to be consistently realized throughout the whole production chains. To achieve this, a knowledge transfer regarding the main principles of Industry 4.0 from Germany to Brazil has to be organized.

The objective of this project is to achieve this knowledge transfer by the development and implementation of Learnstruments for Industry 4.0. Learnstruments are artefacts, which automatically demonstrate their functionality to the learner. They can be used in the classroom or directly at the workplace and aim at increasing the learning and teaching productivity in engineering education. The Learnstruments will enable a knowledge transfer of production principles of Industry 4.0 in the field of vocational, higher and professional education to trainees, students and employees for the work in future manufacturing environments. As first result, this project provides synergy effects for both countries: in Brazil through the access to the latest manufacturing technologies and innovations of Industry 4.0, and in Germany through the efficient and effective horizontal integration of Brazilian factories in the value creation networks. As second result, this project prepares trainees, students and employees in Brazil and Germany for the work in an Industry 4.0 manufacturing environment. This result thus directly contributes to meeting the continuous demand of future engineers and highly skilled employees for the manufacturing sector in Brazil and Germany.

Prof. Dr.-Ing. Holger Kohl (TU Berlin)

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Prof. Dr.-Ing. Henrique Rozenfeld (USP)

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Micro milling process optimization (Micro-O)

The research project aims at improving the micro-production chain to generate knowledge about related process stages, including potential improvements of productivity and quality. It is intended to deepen the use of simulation methods in process optimization. First, the process planning will be focused on the analysis of significant impact factors in micro-machining and on the reduction of processing times. Secondly, the process and machine setup and the micro-machining itself will be investigated focusing on its improvement by using enhanced monitoring and simulation techniques. Finally, the part control will be improved regarding measurement methodologies to effectively and accurately provide part information. In order to consider all these different aspects and their impact on the micro milling chain, the partners join their forces and bring their specific knowledge and experience from different disciplines for jointly contributing to the improvement of micro milling processes based on their particular expertise.

The knowledge and results gained in the fundamental research activities and through the planned cooperation will considerably improve the competitiveness of the research partners together with the possibilities to spread this knowledge and technology to support micro-manufacturing industries in both countries to introduce novel machining processes. This will help micro-manufacturing and especially the mould making industry to reach superior surface quality, tight machining tolerance, shorter machining time with less wear and tear on their machines and tooling. In summary, this project focuses on the development of knowledge and solutions for innovating critical aspects of micro milling processes, concentrating on the production of moulds for micro-featured products, targeting the improvement of productivity, efficiency and on the advancement of strategies for optimising costs and quality. The envisaged research project faces some important challenges described in the scope and framework of the BRAGECRIM and contributes to the objectives expressed in this research initiative and the interests of Brazil and Germany to improve competitiveness and the level in production technology.

Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann (TU Berlin)

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Dr. Luciana Wasnievski da Silva de Luca Ramos (IPT - Institute of Technological Research)

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Influence of the manufacturing process on the subsequent residual stress relaxation in AISI 4140 steel (Phase 3)

This project is tailored according to the Phase 3 goals of the BRAGECRIM research initiative: The sustainable development of the German-Brazilian production chain through innovative technology. An important step towards a product`s life cycle behaviour is the machining process. This process determines the product's surface and subsurface properties. Especially the latter (residual stresses, microstructure and hardness alterations, cracks, etc.) are relevant for fatigue life of the components. However, under mechanical load the subsurface properties might change. The special focus of this project is the residual stress relaxation due to external loads. This mechanism and the interaction with other surface and subsurface properties are not understood. The detailed characterisation of the mechanism of relaxation depending on the machining process will lead to advanced products. The vision of this project is the specific adjustment of surface and subsurface properties by adapted machining process design to optimize fatigue life of components. The investigation of the occurring mechanisms in a collaborative project will promote the knowledge exchange between Germany and Brazil regarding this important matter for cyclic mechanically loaded components.

Prof. Dr.-Ing. Berend Denkena (Leibniz Universität Hannover)

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Prof. Alexandre Mendes Abrão (UFMG)

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Smart Components within Smart Production Processes and Environments - SCoPE

The manufacturing sectors of Brazil and Germany are facing the challenges of global distributed value-added networks, requiring manufacturing companies to cater to customer demands by offering a wide variety of product customizations, to shorten the time to market for new products and at the same time reduce manufacturing costs in flexible manufacturing environments. The research initiative Industry 4.0 encounters these challenges through the application of highly adaptive factories with a high integration of information and communication technology, and new business models. Basis for these "smart factories" are distributed cyber-physical systems within products and manufacturing environments.

The vision of the research project SCoPE is to promote individual physical manufacturing components as information carriers. Information-carrying manufacturing components comprise a digital data representation about their intermediate manufacturing states, their manufacturing history, physical properties, customizations, purpose etc., and utilize this digital data representation for communication-controlled production processes. "Smart components" will be able to autonomously navigate through a cyber-physical production system and to control the manufacturing and assembly procedures applied to them. Potential use cases are the traceability of smart components in distributed manufacturing environments based on internet technology for the establishment of component individual manufacturing histories or the utilization of individual component data in smart assembly processes to achieve optimal component pairings in complex products.

To support the innovative approach of smart components within smart production processes and environments, the underlying data structures and processes have to be developed. Hence, the innovative core of the SCoPE project is the structured specification of component data in an integrated component data model to enable the application of smart components.

Prof. Dr.-Ing Reiner Anderl (TU Darmstadt)

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Prof. Dr.-Ing. Klaus Schützer (UNIMEP)

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Surface Conditioning and Texturization of Cutting Tool Edges for the Optimization of Manufacture Processes - ConTexTool(Phase 2)

Prof. Dr.-Ing. E.h. Dr. h.c. Fritz Klocke (RWTH)

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Prof. Dr. Amilton Sinatora (USP)

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DINTOR - Fundamentals for the Realization and Measurement of Dynamic Torque (Dynamic properties of structural elements for application in dynamic torque standards at primary level) (Phase 2)

Prof. Dr.-Ing. habil. Thomas Fröhlich (TU Ilmenau)

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Prof. Dr.Eng. Herman Lepikson (UFBA)

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i2MS2C - Integrating Intelligent Maintenance Systems and Spare Part Supply Chains (Phase 2)

Project number: BRAGECRIM 022/2012

Satisfactory maintenance is crucial for the operation of complex production systems. Insufficient maintenance - potentially due to missing spare parts - can result in breakdowns of the maintained systems, accompanied by cost effects (downtime costs, costly emergency shipments, etc.), diminishing profits, and a declining customer service perception. Thus, the effective and efficient management of maintenance services and the spare parts supply chain is of major relevance for the operation of complex technical systems. Minimizing downtimes of the maintained system while keeping the supply chain costs within an acceptable range can only be achieved by exact forecasts of system breakdowns. Due to the sporadic character of the demand and the broad range of affected system components, the application of "classical" forecasting methods - e.g. for finished products - does not allow for precise demand predictions and causes low forecast qualities. Therefore, more appropriate methods, including advanced embedded diagnostic/prognostic systems, are required to allow for an efficient planning of respective maintenance activities and spare parts replenishment. Furthermore, supply and distribution of the needed spare parts along the supply chain together with the planning of service personnel are mandatory for effective maintenance.

Prof. Dr.-Ing. Bernd Hellingrath (Uni Münster)

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Prof. Dr. Carlos Eduardo Pereira (UFRGS)

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Development of wear resistant and self-lubricating coatings on sintered steels from Polymer-Derived Ceramics (PDCs) (Phase 2)

It is estimated that about 34% of all energy used in industrial countries is wasted to overcome friction. In addition to energy loss, the generated heat negatively affects the performance of the mechanical system. Thus, high friction results in higher wear and more than 30% of the production in industry goes to replace worn out products. There are many activities worldwide to overcome these problems in industry and to develop components which are less susceptible to friction and wear. In a reciprocal manner friction affects also day-life products (e.g. refrigerator compressors) which work under pressure and metal-metal contact is almost unavoidable. Nowadays many innovative techniques are applied to increase the working-life of a component. Some current solutions to compensate the problem of friction are the use of parts with hard coatings or self-lubricating surfaces. Drawbacks in manufacturing of these coatings are still present. The processing of solid lubricant coated parts involve complex and elaborate steps as well as highly expensive equipment and materials.

In order to increase the energetic efficiency of the products the route of Polymer Derived Ceramic (PDC) seems to be a promising technology regarding to the processing of tailored surfaces on metal parts. The PDC technique is based on the transformation of a mostly silicon based polymer (precursor) into an amorphous SiCN ceramic material by a thermal treatment (pyrolysis) at temperatures up to 1000 °C. Due to the polymeric behavior of the precursor different shaping techniques (dipping, spraying, spin-coating) for applying a coating can be used. The unique structure of the polymers are particularly advantageous for a strong adhesion at the metal surfaces. In order to tailor the coating properties like increasing the hardness, influencing the tribological behavior or adjusting the mismatch in thermal expansion between coating and substrate the polymers can be loaded with additional filler materials, e.g. ceramic or metal particles.

The aim of this project is to develop PDC coatings on sintered, pre-sintered and non-sintered parts. The goal is to obtain a metal component with a wear resistant surface by using hard ceramic phases (e.g. Si3N4 or SiC) in combination with a dry self-lubricant feature represented by ceramics with a low coefficient of friction (e.g. hBN). Thermal treatment of the coated samples in highly reactive environments should exert a positive influence on the coating properties. The processing scientists work together interdisciplinary in order to combine various expertise in the field of metal processing and polymer derived ceramics to develop a new coating technology.

Dr. Günter Motz (Uni Bayreuth)

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Prof. Dr. Aloisio Nelmo Klein (UFSC)

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Manufacturing Process of Nanostructured Deposition Coating (ManuNanoDep) (Phase 1 + 2)

Technical applications of nanomaterials have received special attention due to their desirable characteristics in strategical areas such as catalysis, pigments, health, food, treatment of surfaces, among others. In the engineering field, nanomaterials or nanoparticles have fundamental applications in the development of catalysts and sensors, where the specific process functionality and quality is only achieved in nanostructures with high surface area and small particle sizes below approximately 20 nm. For applications of nanostructured materials, the particle formation and production step as well as the formulation of these particles in terms of surface layers and coatings need to be addressed properly to transfer nanostructured materials into industrial products. In this sense, the development of improved manufacturing processes employing nanoparticles is presented as a strategic theme for the scientific and technological development. Nanoparticles with high purity and narrow particle size distributions can be produced efficiently and economically in pyrolysis reactors e.g. in flame sprays. These reactors are the central core of the FSP process ("Flame Spray Pyrolysis") and are obtained by the combustion processes of drops of a liquid fuel (ethanol, iso-octane, aromatic hydrocarbons). These small drops contain a dissolved (metal) precursor produced by an axial spray in contact with an oxidant sonic jet, with consequent formation of the flaming spray. The main flame typically is stabilized by a pilot flame by burning a premixed gaseous hydrocarbon and the nanoparticles are nucleated in the frontal region of the flame after the evaporation and burning of the fuel and the precursor. In the region of the main flame occurs the entrance of external air which ensures the supply of oxidant oxygen required for complete fuel combustion and oxidation of the precursor and subsequent formation of nanoparticles. The FSP process is capable to produce nanoparticles and mixtures of metal oxide particles with sizes in the range varying from 1 to 100 nm, which are based on low cost metallic precursor materials.

The main objectives of the project may be summarized as:
- Derivation of suitable process conditions for manufacturing of tailored nanostructured coatings.
- Development of suitable in-situ diagnostic techniques for process monitoring (process metrology).
- Development of combined integral process models for description and scaling of nanostructured deposition manufacturing.

Future investigations of the project contain the development of new reactor concepts for simultaneous synthesis of metal oxide and carbon black nanoparticles with specific application in Li-ion-battery manufacturing.

Prof. Dr.-Ing. habil. Udo Fritsching (Uni Bremen)

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Prof. Dr. Henry Franca Meier (FURB)

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Manufacturing of Structured Surfaces via Grinding(Phase 2)

Surface structures are used to extend technical components life. Surface structures, also called functional surfaces, provide additional space for cooling lubricant and favour the generation of pressure in the lubrication film at low sliding speeds. As a consequence, friction in technical components is decreased, resulting in reduced wear. The manufacturing of such structures is nowadays generally done applying lithography, etching, laser techniques and high-precision machining. In this collaborative project, conventional grinding using special grinding wheels with defined topographies will be applied to manufacture structured surfaces, which is only marginally researched so far. Grinding will allow a much faster production of structured surfaces in several kinds of material to improve efficiency and sustainability of materials used in technical components. Besides the defined topographies of the tools, it is essential to know and control the kinematics of the process to be able to manufacture deterministic structures. This will be achieved by deriving analytical equations that specify the kinematics of the proposed grinding process. In this collaborative project, two different kinds of special grinding wheels and kinematics will be developed and researched. The German research group will focus on grinding wheels with defined grain patterns for surface grinding, whereas the Brazilian research group will focus on special conditioning of the bond of grinding wheels applying a cylindrical plunge grinding process. By applying surface and cylindrical grinding, all geometries relevant for sliding components will be considered.

Based on the analytical equations specifying the respective kinematics, each research group will develop a simulation tool. The required grinding wheel patterns accordant to desired structures of the Brazilian Group will be simulated using a pattern generation and mapping software, previously developed at the Brazilian Institute and to be enhanced during the proposed project. The German Research group will develop a simulation tool that is able to identify and visualize needed grain patterns for desired surface structures and vice versa. The manufactured structured surfaces from both groups will be optically mapped and their tribological performance will be evaluated. By comparing the possibilities and limitations of the respective approaches, a comprehensive knowledge of the capabilities of grinding structured surfaces will be achieved. The unrestricted exchange of the research results will lead to results impossible to achieve in individual projects and will strengthen the relationship of this binational research group.

Prof. Dr.-Ing. Jan C. Aurich (TU Kaiserslautern)

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Prof. Dr. Eng. Eraldo Jannone Da Silva (USP)

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Rapid solidification and advanced manufacturing of Cu-based shape memory alloys with complex geometries(Phase 2)

In this project, multicomponent Cu-based shape memory alloys (SMAs) shall be processed by the relatively new technique of selective laser melting, which is expected to result in components with advanced mechanical properties. The alloy powder required for this manufacturing process is synthesised by spray forming. The goals of this project are to study the influence of two rapid solidification methods (spray forming and SLM) on the microstructure and the shape memory effect of two Cu-based SMAs, viz. Cu-11.85Al-3.2Ni-3Mn and Cu-11.35Al-3.2Ni-3Mn-0.5Zr. The mechanical properties shall be analysed with focus on the interrelation between the microstructure (e.g. phase formation, grain sizes, second phase precipitates etc.) and the details of the martensitic transformation (i.e. shape recovery, superelasticity, strength etc.). Moreover, it shall be evaluated whether or not SLM is a competitive costefficient alternative for manufacturing products like stents or actuators/sensors of shape memory alloys with advanced mechanical properties. Considering that high cooling rates can be reached by this method, the influence of rapid solidification on phase formation and grain size, mechanical properties and shape memory effect of Cu-based shape memory alloys will be studied.

Prof. Dr.-Ing. habil. Jürgen Eckert (IFW Dresden)

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Prof. Dr.-Ing. Claudemiro Bolfarini (UFSCar)

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Cutting Behavior and Process Monitoring during Grinding of Ceramics using CVD-Tools (Phase 1 + 2)

Advanced Ceramics have been applied on many areas of engineering and related concerns of microgrinding are aspects of advanced manufacturing that have been growing together. Lenses, mirrors, mechanical parts, medical products, cutting tools, mechanical systems, electronics, armor, chemical, MEMS parts, and a wide variety of sensors are examples for commercial purposes. All these applications need to be manufactured with precise standards using micro grinding techniques. Most of these applications require a crack-free surface. Usually, hard and brittle materials such as glass, silicon, zirconium oxide, aluminum oxide, PZT ceramics and germanium are commonly used for making these products. The advances on micro grinding of brittle materials have led to the discovery of a ductile regime in which material removal is performed by plastic deformation. Fracture mechanics predict that even brittle solids can be machined by the action of plastic flow, as it is the case for metal, leaving crack free surfaces when the removal process is performed at less than a critical depth of cut.

For the processing of piezoelectric ceramics the state of the art shows that further fundamental studies have to be carried out in order to learn about the cutting behavior. Within a first research period basic knowledge about the cutting behavior of PZT ceramic was gained. With this knowledge the basic machinability could be classified. Due to these investigations it is known which parameters and tools are suitable for machining. Additionally, the monitoring process during machining with microgrinding pins could be successfully implemented. However, these studies have been restricted to the production of grooves. Complex structures such as pillar arrays have not been made. Therefore, it is yet not identified what aspect ratios can be achieved in piezoelectric ceramics. Within this funding period the processing of piezoelectric ceramics will be further investigated, based on the results of the initial research project.

In addition, the monitoring process during micromachining is limited. The forces that occur are very low. Moreover, the maximum revolutions of the spindle system have to be very high in order to achieve the re-quired cutting speeds. This is often in the range of the natural frequency of the sensors, so that no proper measurements can be taken. Therefore, special sensors, with natural frequencies outside the excited fre-quencies, have to be used. Conventional positioning methods in macro-scale machining usually reach accu-racies that are not sufficient for micromachining. Therefore, it is necessary to develop process monitoring systems that increase the machining accuracy. So far, the quality of the components is determined outside of the machine. However, it is not possible to clamp the components back in the same position in the ma-chine. Thus, a post-processing of the structures is not yet possible. In addition, micro machining is very time consuming. Early detection of tool failure would therefore lead to a possible reduction of post-processing time. A large proportion of studies that deal with the monitoring process in micromachining focus on geometrically defined cutting especially milling and drilling. Periodic signals are analyzed whereas the change of the signal indicates tool wear. Regarding the monitoring process for micro-grinding only few studies exist. These deal with the use of grinding pins. The influence of tool diameter on the monitoring process has not yet been investigated. In addition studies on the use of a monitoring process in micro-grinding with Dicingblades are lacking. As part of the research project this gap should be closed in order to identify process-tool failure. In the first research period a potential connection between the tool state and the force measurements was found to be verified in the period requested.

Dr.-Ing. Hans-Werner Hoffmeister (TU Braunschweig)

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Prof. Dr. Eng. Rodrigo Lima Stoeterau (USP)

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Cognitive Production Metrology for Flexible Small Series Production (Phases 1+2)

The trend for product individualization results in a demand for small and more flexible production series. The improvement of production flexibility increases the control complexity of the manufacturing tasks, leading to big challenges for quality assurance systems. The major challenge faced by a quality assurance system applied to small series production is to guarantee the needed quality level already at the first run (first time right on time). This demands a constant adaption of the quality assurance system behavior according to the dynamic manufacturing conditions, which can be achieved by the improvement of cognitive and autonomy aspects of the manufacturing systems. The innovative concept of Cognitive Metrology focuses on increasing the manufacturing efficiency and quality within small series through the capacitation of flexible and adaptive production metrology.

Prof. Dr.-Ing. Robert Schmitt (RWTH Aachen)

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Prof. Dr.-Ing. Marcelo Ricardo Stemmer (UFSC)

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Methods for fast setup and robust dimensional measurements with industrial X-ray computed tomography(Phase 1+2)

X-Ray computed tomography (CT) is an emerging non-destructive technology for the dimensional measurement of precision plastic parts with complex geometry. With CT this geometry can be acquired holistically, i.e. including both interior and exterior features, at very high point density. However, CT is a complex process with many influencing factors and non-linear interdependencies. Up to now the optimization of dimensional CT measurements eludes a holistic analytic description. So, currently the set-up parameter values are defined based on the user expertise. By this it remains uncertain if the chosen set-up is metrologically the optimal one. Also the finding of task-adapted parameter values can be elaborate and time-consuming. So the task is the efficient definition of these values returning the smallest uncertainty in measurement for a given CT device.

Prof. Dr.-Ing. Robert Schmitt (RWTH Aachen)

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Prof. Dr.-Ing. Carlos Alberto Schneider (CERTI)

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Scientific Fundamentals for the Realization and Measurement of Small Torques (DEBRATOR) (Phase 1)

The number of small-torque applications in science and technology is growing. Well known examples are micro screws, micro tools, micro gears and micro actuators. But small torques arises as well e.g. in screwing and joining processes in mass production and in a number of micro mechanical devices like digital mirror devises and angular sensors. For the automated processes and to guarantee a high product quality, the small torques should be known with an adequate accuracy. Therefore, a closed traceability chain for the physical quantity torque, especially for small torques is needed. The current state of the art does not meet the requirements. This fact raises the need of a new primary Torque Standard Machine (TSM) for small torques with reduced relative uncertainty.

Prof. Dr.-Ing. René Theska (TU Ilmenau)

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Prof. Dr. Herman Augusto Lepikson (UFBA)

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Emulsion Process Monitor in Metalworking Processes (EPM) (Phases 1+2)

Metal working fluid emulsions (MWF) tend to separate over their life time caused by mechanical, thermal and biological stress in the manufacturing process. This quality and stability change of the MWF alters the physical and chemical properties as well as the machining performance. This loss of fluid stability is a big challenge for the monitoring and quality management of the machine operation. Moreover, this leads to increased costs and environmental problems, since the tapped fluids have to be refilled, recycled (environmental best-case after complete phase separation) or disposed (environmental worst case; e.g. thermal treatment). Thus, there exists a strong need for an easy to use in-situ monitor of the stability of metal working fluids that enables real time response in order to keep machine performance.

In order to minimize consumption of metal working fluids in manufacturing processes, the overall project goal is the "Development of a device for continuous in-process control of MWF quality and stability". The project is focused on the development of the measuring device and suitable data treatment leading to the interconnected project modules:

- Development and testing of the device,

- Destabilization mechanics of metal working fluids,

- Data treatment (neural networks and/or numerical algorithms),

- Coupled coalescence and CFD models for MWF,

which intend to enhance the understanding of coalescence as well as to contribute to an improved environmental and economical balance of the metal working process.

Prof. Dr.-Ing. habil. Udo Fritsching (Uni Bremen)

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Prof. Dr. Roberto Guardani (USP)

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Federative Factory Data Management based on Service Oriented Architecture and Semantic Model Description on XML and RDF for Manufacturing Products (FedMan) (Phases 1+2)

A Federative Factory Data Management has to support the factory data capturing in the early phases of Factory Planning Process. Data capturing from involved domains is a key factor for a flexible production environment. Involved domains are "Product Development", "Process Planning", "Resource Planning", "Production Control" etc.

Factory Planning Process can be characterized as a bridge between "Product Development" and "Production Control" within the "Product Creation Process". Generated factory data are results of the usage of domain-specific IT tools (e.g. CAD, CAM, ERP, etc.). Consequences are deficits in data storage and data redundancies. Possibility to handle this is a consistent IT tool-integration by a system like a Federative Factory Data Management.

Goal of 1st project phase is the development of a Federative Factory Data Management to support the integration of factory data resulting from domain-specific IT tools. A reduction of redundant, heterogeneous and inconsistent data storages has to be achieved. Core is the federative integration of IT tools by the usage of web services.

A running concept of Federative Factory Data Management is the basis for an app-based FedMan. (Mobile-FedMan). App-based extensions of Federative Factory Data Management functionalities have to be developed:

- Consideration of roles and views

- Integration of Material Flow Simulation as planning verification

- Ensuring of data security

Goal is the access of intermediate states of products, processes and resources at any time directly from shop-floor of a factory.

Prof. Dr.-Ing. Reiner Anderl (TU - Darmstadt)

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Prof. Dr.-Ing. Klaus Schützer (UNIMEP)

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A Quick Test Method for the Characterization of In-process Properties of Conventional Grinding Wheels (Phase 1)

Conventional grinding wheels comprising sintered corundum present capable solutions for efficient hightech manufacturing tasks. The performance of this tool category depends substantially on the grinding wheel specification and the conditions in the wheel manufacturing process. Until now the wheel selection for specific manufacturing processes is mostly based on long lasting experiences and implicit knowledge. Significant findings concerning the interaction of the common sintered grain types with the available fused grain types are so far barely known. Information about optimized sintered grain proportions regarding productivity and cost is only sporadic available. A quick test method is therefore fundamental for explicit appraising the performance of innovative wheel specifications. Applying it in an industrial environment will substantially improve the efficiency of developing customized wheel specifications.

Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann (TU Berlin)

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Prof. Dr.-Ing. Walter Lindolfo Weingaertner (UFSC)

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Holistic Optimization of Sculptured Surfaces Manufacturing (HoliMan) (Phases 1+2)

The pressure on the worldwide mould and die industry has been continuously increased due to the constant growth in international competition. In order to remain competitive, the leading industries must increase its productivity by reducing machining time and costs while, increasing the product quality. High Speed Cutting (HSC) and High Performance Cutting (HPC) have the potential to fulfill these demands. However, investigations for increasing productivity lead to time consuming and costly experiments. Furthermore, in many cases the results of experiments performed under controlled environment, cannot simply be assigned to other machines andnconstraints. Therefore, it is necessary to deepen the understanding about processes, machine tool behavior and their relations that impact the manufacturing quality and productivity, by focusing on a holistic optimization of sculptured surface manufacturing.

Prof. Dr. h. c. Dr.-Ing. Eckart Uhlmann (TU Berlin)

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Prof. Dr. Alvaro J. Abackerli (UNIMEP)

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Bulk metal formed parts for power plants (Phases 1+2)

Modern facilities for energy production need very large components fulfilling increasing requirements with respect to their material properties. This implies that the related forming processes are optimized with respect to metal flow as well as microstructure evolution. The overall goal of the project is to investigate procedures allowing to optimize complex incremental forging processes using numerical process simulation in connection with automatic optimization. The chosen example are large forged hollow shafts for wind turbines which could significantly save weight compared to currently forged solid shafts or cast hollow shafts. However this requires that the microstructure achieved is fine and homogeneous enough to allow ultrasonic testing with high resolution.

In the first project period a parametric description for simulation of incremental forging of hollow shafts and evaluation criteria for the simulation results have been developed. Using these numerical tools and experiments a forging strategy for a simplified short hollow shaft was successfully planned and realized on the 6.3 MN forging press focusing on the optimization of metal flow.

In continuation of the close cooperation with the Brazilian partner LdTM (Laboratório de Transformacao Mecânica - Federal University of Rio Grande do Sul, Brazil) the second project period is dedicated towards further development of the numerical tools and their exemplary application to a more realistic and complicated demonstrator geometry, now including optimization of the microstructure development. In the case of successful validation of this procedure the models shall be applied to study which scaling effects are to be expected when scaling up from model size to realistic size.

Prof. Dr.-Ing. Gerhard Hirt (RWTH Aachen)

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Prof. Dr.-Ing. Lírio Schaefer (UFRGS)

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Integrated design and evaluation of logistic networks - Highly Extensible Life-Cycle Oriented Placement of the Order Penetration Point (Phases 1+2)

- Today`s automotive industry is still concentrated on efficiency, individual production processes and financial objectives such as market share. Meeting customer demand for highly customizable vehicles leads to an increasing number of variants and growing complexity. In combination with increasing market dynamics customer orders are more and more unpredictable.

- In order to lower costs and inventory levels while still being responsive to customer needs, it is beneficial to retain a (intermediate) product in a neutral product status in an automotive supply chain as long as possible.

- For Brazil, German automotive OEMs and their local productions play an important role (vice-versa). Thus this especially holds true for the resulting long and global supply chains as being implemented with this emerging market.

- Therefore, the placement of the order penetration point (OPP) is a key decision in supply chain design for emerging markets since the product will be differentiated according to the customers` requirements only after the OPP.

Prof. Dr.-Ing. Axel Kuhn (TU Dortmund)

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Prof. D. Sc. Luiz Felipe Scavarda (PUC-RJ)

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Production of EDM Electrodes by Layer Manufacturing Technique (LMT)(Phase 1+2)

This project is inserted into the agreement reached between Technische Universität Clausthal - TUC and Pontifícia Universidade Católica do Parana - PUCPR and as well as into the strategic interest of the BRAGECRIM Program. This project has the aim of developing and improving technologies on producing precision EDM electrodes by "Layer Manufacturing Technique" (LMT) to create Electro-Discharge Machining advanced 3D products. During the first phase of this project different metal powders will be created and investigated for their EDM properties. The electrodes will be manufactured with different materials using LMTechnique based on Laser sintering via IMW-TU Clausthal facilities. The necessary powder material blends will be obtained using powder metallurgy know-how from the ZFW-TU Clausthal. The assessment and improvement of EDMachining performance measures will be in charge of LAUS-PUCPR. The partners` collaborative work will enable the specification of electrodes geometries and materials applicable for precision EDMachining. In the second phase, the previously developed results will be applied to complex electrodes. Furthermore the wear rate and precision of the electrodes will be improved by optimizing of the post/building-processing steps and powder properties. Moreover, the EDM performance of a real industrial and hybrid electrode (LMT skin and standard core) will be analyzed. This project will finally establish a fast LMT-EDM process chain for small complex products in different application fields, one example could be dental prostheses. The complex shaped electrodes will be manufactured with the defined materials of the first period. The expected outputs are the electrode performance correlating EDMachining and LMT variables, the specification of adequate materials and post processing e.g. coatings for LMT-EDM electrodes, the development of EDM technology tables and procedures for design and fabrication of precision electrodes and an envelope with adequate process EDM parameters settings. The project results will be tested on a real industrial application of a particular electrode geometry using an adequate EDM procedure. The sustainable development of the German-Brazilian production chain through innovative technology is considered in this project. The project will not only be an opportunity to manufacture EDM electrodes, but also to establish a communication channel for technology and human resources transfer between TU Clausthal and PUCPR linked to the Brazilian/German industries.

Prof. Dr.-Ing. Armin Lohrengel (TU Clausthal)

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Prof. Dr. Fred Amorim (PUC-PR)

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LogGlobal - Improving Global Supply Chains(Phases 1+2)

Manufacturing supply chains source raw material on a global scale, utilize regional cost advantages for production and embed partners with outstanding expertise in their networks. Their goal is to create and to sustain a competitive and reliable network that can cope with unexpected perturbations. To this end, decentralized operations need to be precisely synchronized in order to materialize their potential benefits. However, operational planning and control activities are quite often performed in a disconnected manner, being limited to a function / department-oriented view. The aim of the research project is to develop and implement new concepts, methods and management policies for planning and control of integrated production and transport systems on the operational level. By their combination this integration will allow for a better synchronization of material flows, enhanced competitiveness and a better handling of perturbations.

Prof. Dr.-Ing. Bernd Scholz-Reiter (Uni Bremen)

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Prof. Dr. Eng. Antonio G. N. Novaes (UFSC)

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Low-cost and reliable production of oxide ceramic matrix composites(Phases 1+2)

For advanced ceramic composites, affordable manufacturing is still the most essential shortcoming with respect to successful commercial use. This holds particularly for components made out of composites with complex hierarchical structures and high demands of mechanical performance and reliability at the same time. This is the case of Fibre-Reinforced Ceramic Matrix Composites (FRCMCs), which have been developed to overcome the intrinsic brittleness and lack of reliability of monolithic ceramics. Their major advantages include high temperature capability, light weight, good corrosion resistance and adequate damage tolerance. There is a wide spectrum of FRCMCs depending on the chemical composition of the matrix and reinforcement, although at present only Cf-C/SiC composites produced by the silicon infiltration route have obtained commercial production level. However, fibre reinforced composites based on oxides (Oxide-Oxide FRCMC) would offer essential advantages with respect to long time stability in oxidizing atmospheres. Although in the past decades there has been a considerable interest in Oxide-Oxide FRCMC, only a few production concepts meet the requirements in view of cost and performance so far. The present work aims at reducing the production costs of FRCMCs by using a combination of conventional powder metallurgy routes and well-known production concepts existent for manufacturing polymer matrix composites, in an approach based on the prepreg technology. Additionally, reactive based matrices such as Reaction Bonded Aluminum Oxide (RBAO) will be used, which will lead to advanced performance and reliability by enabling the consolidation of defect-free oxide matrices. Advanced shaping techniques based on CAD/CAM concept (rapid prototyping by LOM) will be additionally integrated, favouring easy small scale manufacturing, which is in general very typical for these materials.

Dr.-Ing. Rolf Janßen (TU Hamburg-Harburg)

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Prof. Dr.-Ing. Dachamir Hotza (UFSC)

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Investigation and improvement of a manufacturing process chain from cold drawing processes to induction hardening (Phases 1+2)

Manufacturing processes in general consist of materials solidification processes, metal forming processes and more than one straightening process, machining and heat treatment. Machining and final straightening is then necessary to guarantee the required shape and dimensions of machine parts. Cold forming processes are energy efficient and clean and are used in production processes with an increasing number. Cold forming on the other hand significantly changes materials properties and automotive parts still need a surface heat treatment or have to be through hardened completely to fulfill strength requirements. An improvement of properties during one production step consequently can result in problems in the next, one of the following or finally in the last manufacturing step. The transmission of distortion potentials from one manufacturing step to the other in a cold drawing processing line with additional induction hardening is analyzed experimentally and partially modelled. A DoE-plan (design of experiments) of main affecting parameters is used to identify effects and correlations. A reduction of one or more manufacturing steps or ideas to implement changes and select parameters that minimize distortion is expected.

Goals: The as far as possible observation of materials properties, parameters of the involved cold drawing process, straightening and polishing operations as well the involved cutting operations and the final induction heat treatment were the central aims of the planned international cooperation. The identification of the 5 to 6 main important process parameters for the activation and the generation of distortion potentials by means of the method of design of experiments (DoE) would be able to identify statistically significant process parameters and ideally to mi-nimize manufacturing operations as e.g. additional machining. Consequently Distortion Engineering is the knowledge of distortion potential carriers in each manufacturing step and the use of compensation potentials in each of these.

Prof. Dr.-Ing. Thomas Hirsch (Uni Bremen)

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Prof. PhD. Alexandre da Silva Rocha (UFRGS)

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Analysis and simulation of the polishing process of porcelain stoneware tiles (Phases 1+2)

The current industrial polishing process of stoneware tiles is considered energetically inefficient, and though undesired glossiness gradients may occur onto the polished surface, known as "polishing shadows".

Jun.-Prof. Dr.-Ing. Fabio J. P. Sousa (TU Kaiserslautern)

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Prof. Dr. Eng. Orestes E. Alarcon (UFSC)

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Remanufacturing oriented Production Equipment Development (Phase 1+2)

- Remanufacturing enables to close the material loop at the end of life cycle of equipment minimizing the environment impact

- Brazil and Germany need sustainable technologies to meet challenges of 21st century

- Sustainability viewed from the perspective of production technology essentially represents the increase of usage efficiency of resources.

- General societal, economic and ecological conditions compel a rethinking from the traditional industrial society to the sustainable design of value creation nets.

- In order to reduce the consumption of resources, a rethinking to a closed loop economy is required

Prof. Dr.-Ing. Guenther Seliger (TU Berlin)

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Prof. Dr. Eng. Henrique Rozenfeld (USP)

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