Technology Sheets

Creating functionalities with laser texturing

Femtosecond lasers are ultra-fast pulsed lasers, which are used to remove material. The material is not heated, but immediately turns into a plasma. In addition, the technology is extremely suited for the very precise application of functionalities via textures.

What a mobile cobot can do in production

Our consortium partner, Sirris, was given the opportunity to make temporary use of a KMR iiwa with the aim to extensively test and explore the potential of a mobile cobot.

Cryogenic machining, also for soft(er) materials

Cryogenic cooling during machining stands for machining at very low temperatures. This has advantages both for tools made of heat-resistant materials, where the heat can be high during machining, and for the machining of softer materials, which will flow more easily during machining.

Cryogenic cooling: an overview

Almost 10 years after the introduction of cryogenic machining, a lot of research has been conducted on this technology, its application and pros and cons. However, despite the positive results, the step to the industry does not seem to be so obvious.

Environmental impact of cryogenic machining

Sometimes the question arises to what extent cryogenic cooling is environmentally-friendly, as the gases used are a consumable, unlike other refrigerants that can be reused. Cryogenic processing does have interesting environmental advantages.

What is a Digital Twin?

The first idea of Twin appeared at NASA with its Apollo program. At that time, it was a real copy of the module where it was possible to reproduce the problems encountered in space by the module and find a way to solve them from the earth. Grieves introduced the transformation into a Digital Twin in 2003 as mentioned in “Digital Twin: Manufacturing Excellence through Virtual Factory Replication”. NASA and the US Air Force then started to apply the Digital Twin in the aeronautic domain.

Collaborative Robotics

Industrial automation and robotics are nothing new within manufacturing. However, a new paradigm is emerging which blends manual and robotic activities. Where traditional automation solutions have been isolated from human workforce for safety reasons, new sensorised and aware robotic systems – or collaborative robotic systems (Cobotics) - are now becoming common place.

AR meets Industry

When you hear AR, for sure you are thinking about the heavy, chunky, massively overpriced Hololens and how you tried to somehow see something with the small field of view. We don’t even have to talk about the hard time you had trying to tap on virtual objects in the air.

 

Additive manufacturing vs conventional machining process for complex geometry parts

Conventional machining process like milling, drilling, rolling, forming and so on, are still the most common go-to manufacturing operations for medium to large volume production. Additive manufacturing (AM) has been disrupting the manufacturing environment in the past decade with new possibilities for customised small volume production. Optimised manufacturing, for example, is very difficult to achieve with conventional machining processes, whereas with the help of additive manufacturing, this is easy with relatively fewer tooling changes, and much less time involved with the manufacturing operation.

Digital Twin Applications in Manufacturing

Introduction

Developments and advancements in digital technologies have challenged traditional manufacturing and become the basis of what is known as the Fourth Industrial Revolution or Industry 4.0.

A new method for finishing 3D Near Net Shape components

‘Near Net Shape’ components (NNS) are products that are almost in their final or finished form, and just need some finishing work in order to come within the required specifications, such as dimensional precision and surface roughness. Removal technologies are still the most common processes used for making the final finish that leads to the functional product. Therefore tool path generation for controlling CNC machines is essential.

Epicycloidal milling is up to 20 % faster than trochoidal milling

Among the different working strategies for ‘high performance cutting’ (HPC), trochoidal milling is an efficient way of processing (difficult materials), and is one that also utilizes a longer cutting edge. In order to increase productivity even further, (i.e. reducing the cycle times) the materials and processes laboratory at University of Karlsruhe has developed another strategy for trochoidal cutting, namely epicycloidal cutting.

Predictive Maintenance

End-to-end digitisation of physical assets within a value chain and their integration into a digital ecosystem is the focus of the fourth industrial revolution [1]. Ubiquitous sensors and microprocessors installed on machines, embedded systems and smart devices along with the increasing horizontal and vertical networking of value chains will result in unprecedently seen amounts of data.

Robot significantly reduces production time of large moulds

The arrival of machine hammer peening opens the way to fast finishing of large milled injection and deep drawing moulds. Instead of manual polishing, an industrial robot does the work in a shorter time. This process also offers a number of other advantages.

Machining electrically conductive ceramics with spark erosion (EDM)

Because of their extreme hardness, ceramic materials and their composites are very popular for mechanical applications that are susceptible to wear and tear due to heavy loads. The other side of the coin is that conventional techniques do not usually suffice to work these materials. Some are even impossible to grind, because oxides deposit on the grinding wheel.