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  • 1. Benecke, Stephan
    et al.
    Neugebauer, Sabrina
    Peukert, Bernd
    Nissen, Nils F.
    Uhlmann, Eckart
    Lang, Klaus-Dieter
    Sustainability assessment for wireless micro systems in smart manufacturing environments2015In: USB Proceedings of the 9th International Symposium on Environmentally Conscious Design and Inverse Manufacturing: Sustainability through innovation in product life cycle design, 2015Conference paper (Other academic)
  • 2. Garretson, Ian C.
    et al.
    Peukert, Bernd
    Tech Univ Berlin, Inst Machine Tools & Factory Management, Berlin, Germany.
    Linke, Barbara S.
    Uhlmann, Eckart
    Hypothetical Sustainability Axioms for Axiomatic Design With an Application in Grinding Machine Design2017In: Proceedings of the 12th International Manufacturing Science and Engineering Conference, New York: AMER SOC MECHANICAL ENGINEERS , 2017, p. 1-10Conference paper (Refereed)
    Abstract [en]

    The design of a high precision machine tool presents one main goal for an engineer: to maximize productivity while minimizing resource inputs and wasted outputs. Incorporating additional design requirements to improve the sustainability of the machine tool presents challenges to design engineers. Should productivity be sacrificed for resource efficiency improvements? Previous tools used for incorporating sustainability principles into design provide guidance but lack necessary detail for making informed decisions, or the tools rely on the engineer's previously developed knowledge in sustainable design. Axiomatic design, being an already accepted system design framework, provides an opportunity to incorporate sustainability considerations into the core of design activities rather than having sustainability be a side activity. A methodology for designing sustainable machine tools using axiomatic design is presented, and a case study on a grinding machine is investigated. A list of hypothetical sustainability axioms are proposed, similar to how the original axioms of axiomatic design were proposed. The axioms are then discussed using the example of a grinding machine tool. Copyright © 2017 ASME.

  • 3. Kianinejad, Kaveh
    et al.
    Uhlmann, Eckart
    Peukert, Bernd
    Department for Machine Tools and Factory Management, Technical University.
    Investigation into Energy Efficiency of Outdated Cutting Machine Tools and Identification of Improvement Potentials to Promote Sustainability2015In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 26, p. 533-538Article in journal (Refereed)
    Abstract [en]

    Cutting machine tools have a significant impact on manufacturing and sustainability. There exist a large number of outdated cutting machine tools especially in developing and emerging countries which are still taking a considerable share in global value creation. Furthermore, an increasing trend in field of reuse, retrofitting and upgrading can be observed. For Life-Cycle-Assessment and analyses of end-of-life behavior of such machine tools in context of sustainability, reliable values for energy consumption and machining efficiency under realistic machining conditions are indispensable. In the present paper the energy consumption and machining efficiency of an exemplary outdated milling machine have been measured and analyzed under consideration of different influences such as process parameter, machining material and ratio of prim time to secondary time. Additionally a comparison between a newer and the outdated milling machine has been carried out in order to identify and quantify possible improvement potentials of outdated machine tool concerning energy consumption and machining efficiency. Based on obtained results more accurate and realistic decision can be made by enterprises who aim to promote sustainable manufacturing. © 2015 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license.

  • 4. Peukert, Bernd
    et al.
    Benecke, Stephan
    Clavell, Janire
    Neugebauer, Sabrina
    Nissen, Nils F.
    Uhlmann, Eckart
    Lang, Klaus-Dieter
    Finkbeiner, Matthias
    Addressing sustainability and flexibility in manufacturing via smart modular machine tool frames to support sustainable value creation2015In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 29, p. 514-519Article in journal (Refereed)
    Abstract [en]

    Sustainability and flexibility are crucial aspects in todays’ manufacturing processes. Within this study an innovative approach of modular machine tool frames (MMTF) equipped with micro system technology is presented that aims at enhancing flexibility of mutable production processes. This new approach extends the existing reconfigurable manufacturing systems (RMS). MMTF goes beyond the platform approach via minimizing the machine tool frame parts used for the building block system of manufacturing cells. The concept has been realized by integration of modularized microelectronics and actuators enabling for integrity and accuracy of the machine tool frame.

    In this contribution, sustainable hotspots for the production of the MMTF are identified via a tiered life cycle sustainability assessment. From these findings, new approaches are derived that provide for a reasonable usage of mechanical and electronic components in MMTF for sustainable value creation.

  • 5. Peukert, Bernd
    et al.
    Mewis, Jan
    Saoji, Mihir
    Uhlmann, Eckart
    Benecke, Stephan
    Lang, Klaus-Dieter
    Thomasius, Rolf
    Nissen, Nils F.
    Microsystem enhanced machine tool structures to support sustainable production in value creation networks2013In: Proceedings of the 11th Global Conference on Sustainable Manufacturing / [ed] Günter Seliger, 2013Conference paper (Refereed)
    Abstract [en]

    The modularization of machine tool frames is a promising approach to support sustainable manufacturing in global value creation networks. The idea of designing single versatile lightweight and accuracy optimized (LEG²O) modules allows for innovative concepts with respect to mobility, configurability and adaptability. This contribution focuses on possible use-case scenarios that involve modular machine tool frames equipped with microsystems providing enabling functionalities, e.g. self-identification and provision of additional sensor data. The study provides a profound overview of potential capabilities and limitations of the proposed concept. As replacement, reuse and upgrade of single parts become critical issues when considering the complete product lifecycle, the question on how electronics integration can successfully contribute to a sustainable usage is investigated.

  • 6. Peukert, Bernd
    et al.
    Saoji, Mihir
    Uhlmann, Eckart
    An evaluation of building sets designed for modular machine tool structures to support sustainable manufacturing2014In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 26, p. 612-617Article in journal (Refereed)
    Abstract [en]

    The modularization of machine tool frames is an approach when designing new machine tool structures in a sustainable context. By integration of microsystem technology and designing lightweight modules, a smart alternative to conventional machine tool frames is developed. In previous studies, this concept has been evaluated along with a compilation of the possible use-case scenarios and the potential benefits from using modular electronics. In the presented paper, the geometric requirements from the selected use-case scenarios for machine tool structures are identified by dividing the structures in their ideal mechanic equivalents. A set of rules is developed driven by the generalized geometric requirements of the machine tool frames. Three different approaches of polyhedral building sets are shown and evaluated for their merits based on criteria of geometric functionality and sustainability. Finally, a prototypical modular portal frame is presented for the proof of concept.

  • 7. Uhlmann, Eckart
    et al.
    Lang, Klaus-Dieter
    Prasol, Lukas
    Thom, Simon
    Peukert, Bernd
    Benecke, Stephan
    Wagner, Eduard
    Sammler, Fiona
    Richarz, Sebastian
    Nissen, Nils F.
    Sustainable Solutions for Machine Tool2017In: Sustainable Manufacturing: Challenges, Solutions and Implementation Perspectives / [ed] Rainer Stark, Günther Seliger, Jérémy Bonvoisin, Cham: Springer, 2017, p. 47-69Chapter in book (Refereed)
    Abstract [en]

    Environmental, economic and social changes of any significant proportions cannot take place without a major shift in the manufacturing sector. In today’s manufacturing processes, economic efficiency is realised through high volumes with the use of specialised machine tools. Change in society, such as in the form of mobility and digitisation, requires a complete overhaul in terms of thinking in the manufacturing industry. Moreover, the manufacturing industry contributes over 19 % to the world’s greenhouse gas emissions. As a consequence of these issues, a demand for sustainable solutions in the production industry is increasing. In particular, the concept of “cost” in manufacturing processes and thus the “system boundaries” within the production of the future has to be changed. That is, a great number of aspects to the machine tool and production technology industries can be improved upon in order to achieve a more sustainable production environment. Within this chapter, the focus lies on microsystem technology enhanced modular machine tool frames, adaptive mechatronic components, as well as on internallycooled cutting tools. An innovative machine tool concept has been developed recently, featuring a modular machine tool frame using microsystem technology for communication within the frame, which allows for a high level of flexibility. Furthermore, add-on upgrading systems for outdated machine tools—which are particularly relevant for developing and emerging countries—are poised to gain in importance in the upcoming years. The system described here enables the accuracy of outdated machine tools to be increased, thus making these machine tools comparable to modern machine tool systems. Finally, the cutting process requires solutions for dry machining, as the use of cooling lubricants is environmentally damaging and a significant cost contributor in machining processes. One such solution is the use of internally cooled cutting tools.

  • 8. Uhlmann, Eckart
    et al.
    Mewis, Jan
    Baldo, Christian
    Ramos, Luciana
    Peukert, Bernd
    Schützer, Klaus
    Conte, Erik G. D.
    Tamborlin, Marcelo O.
    Virtual machining of micro-milling processes for prediction of cutting forces and surface quality2017Conference paper (Refereed)
  • 9. Uhlmann, Eckart
    et al.
    Peukert, Bernd
    Erhöhen der Dämpfung hohler Leichtbaustrukturen2015In: wt Werkstattstechnik online, Vol. 105, no 7/8, p. 446-450Article in journal (Refereed)
    Abstract [en]

    Machine tool manufacturer use lightweight designs to reduce resource consumption and lower the machine inertia. In the context of high dynamic machinery, damping properties become important. Hereby, research is carried out in the fields of actuators or the manipulation of machine tool control to actively improve damping properties. In contrast to that, the following text describes a passive approach to increase the structural damping of hollow structures by filling up with environmentally harmless materials.

  • 10. Uhlmann, Eckart
    et al.
    Peukert, Bernd
    Technische Universität Berlin, Pascalstraße 8-9, Berlin, 10589, Germany.
    Reconfiguring machine tool behavior via smart building block systems2019In: 7th International conference on Changeable, Agile, Reconfigurable and Virtual Production (CARV2018), Elsevier, 2019, Vol. 28, p. 127-134Conference paper (Refereed)
    Abstract [en]

    The reconfigurability of manufacturing systems is conventionally increased by utilizing concepts of modularization and platforms. At this moment, the actual reconfigurability is often limited to a priori designed reconfiguration variants for the production within single part families. There is only a little research on reconfiguring the mechanical behavior of machine tool frames. This paper presents an innovative approach for reconfiguring the mechanical behavior based on smart building block systems. Topologically optimized polyhedral building blocks are mechanically bolted to form different machine tool frame configurations. A high grade of modularization allows for the assembly of individualized topologies for different manufacturing scenarios "as needed when needed". The increase in reconfigurability results from the high geometric flexibility of the proposed building block system. However, successful implementation relies on quick and robust simulation approaches for calculating the machine tool frame characteristics before the actual assembly process. Within this paper, a time-efficient approach based on the sub-structuring methodology is utilized. The presented approach consists of forming superelements by performing a GUYAN reduction on the building blocks to extract the stiffness behavior. A Component Mode Synthesis is used to extract modal information. The ANSYS Parametric Design Language is then used to automatically couple the modules according to a customized descriptive machine tool language. A simple joint model is implemented and experimentally fitted with a two-block configuration. The two-block configuration is then extrapolated to a full machine tool frame portal. An example of changing the modal characteristics of this machine tool frame portal is presented in the form of numerical results.

  • 11. Uhlmann, Eckart
    et al.
    Peukert, Bernd
    Technical University of Berlin.
    Prasol, Lukas
    Könnecke, Konstantin
    Value Co-Creation in Living Factories based on Shared Manufacturing Equipment2016In: Konferenzband der 1. Interdisziplinäre Konferenz zur Zukunft der Wertschöpfung, 2016, p. 199-208Conference paper (Refereed)
    Abstract [en]

    Global challenges that define 21st century in retrospective will be poverty, excessive use of the biosphere and the depletive exploitation of scarce material and energetic resources. Hereby, manufacturing technology is one of the main drivers for resource consumption. The BRUNDTLAND report of 1987 proposed sustainable technological development by minimizing negative effects associated with new technologies. From a production technology point of view, this challenge of sustainability development is directly related to the hypothesis of sustainable value creation networks. As new information technology enables for rapidly changing business models, it is now mandatory to analyze the solution space for sustainable value creation by implementing maturing sustainable technologies on a conceptual level and develop application scenarios for their usage. One promising approach is Shared Manufacturing Equipment in distributed manufacturing facilities, so-called Living Factories, to foster value co-creation and co-opetition. Adaptable and scalable machine tools may function as an enabler for this idea. The paper describes the application of Shared Manufacturing Equipment and the conceptual basis of a new manufacturing approach based on modular, adaptable machine tools, so-called Reconfigurable Machine Tools. It shows interlinks to potential benefits and describes potential barriers and pitfalls by implementing Living Factories.

  • 12. Uhlmann, Eckart
    et al.
    Peukert, Bernd
    Technical University of Berlin.
    Thom, Simon
    Prasol, Lukas
    Fürstmann, Paul
    Sammler, Fiona
    Richarz, Sebastian
    Solutions for Sustainable Machining2017In: Journal of manufacturing science and engineering, ISSN 1087-1357, E-ISSN 1528-8935, Vol. 139, no 5, p. 051009-1-051009-7Article in journal (Refereed)
    Abstract [en]

    The manufacturing industry contributes over 19% to the world’s greenhouse gas emissions (U.S. Energy Information Administration, 2008, “Rep: Annual Energy Review 2008,” Report No. DOE/EIA-0384; Diaz et al., 2010, “Environmental Analysis of Milling Machine Tool Use in Various Manufacturing Environments,” 2010 IEEE International Symposium on Sustainable Systems and Technology.) and 31% of the total energy consumed annually in the U.S. (Herzog, T., 2005, “World Greenhouse Gas Emissions in 2005,” World Resources Institute, Washington, DC 2 ; Diaz et al., 2010, “Environmental Analysis of Milling Machine Tool Use in Various Manufacturing Environments,” 2010 IEEE International Symposium on Sustainable Systems and Technology.). There is therefore an increasing demand for sustainable solutions for the production technology industry. At the Technische Universitat (TU) Berlin, Germany, a collaborative research center (CRC) is focusing on new solutions for the sustainable machining of high performance alloys, with developments from machine tool frames to cutting tool technology being undertaken. An innovative machine tool concept with a modular frame, which allows a high level of flexibility, has been developed. Furthermore, add-on upgrading systems for older machine tools, which are particularly relevant for developing countries, have been developed. These systems allow the accuracy of outdated machine tools to be increased, thus making the machine tools comparable to modern systems. Finally the cutting process also requires solutions for dry machining, as the use of cooling lubricant is environmentally damaging and a significant cost contributor in machining processes. Two solutions are being developed at the TU Berlin: an internally cooled cutting tool and a heating concept for ceramic tools to allow dry machining of high temperature alloys, for example, for the aerospace industry.

  • 13. Uhlmann, Eckart
    et al.
    Polte, Mitchel
    Blumberg, Julian
    Peukert, Bernd
    3-Achs-Portalfräsmaschine als Demonstrator für ein modulares Werkzeugmaschinengestell2019In: Zeitschrift für wirtschaftlichen Fabrikbetrieb, Vol. 114, no 9, p. 245-248Article in journal (Refereed)
  • 14. Uhlmann, Eckart
    et al.
    Saoji, Mihir
    Kushwaha, Shashwat
    Peukert, Bernd
    Optimierte Sensorplatzierung in Mess-Netzwerken: Vorhersage von temperaturbedingter Verlagerung auf Basis reduzierter und verteilter Sensordaten2014In: wt Werkstattstechnik online, E-ISSN 1436-4980, Vol. 104, no 5, p. 266-271Article in journal (Refereed)
    Abstract [en]

    The following article presents a methodology for optimized sensor allocation. The approach is used for the calculation of temperature induced displacements of the Tool Center Point of machine tools. An algorithm based on the reduction of data and a linear least square estimator is presented. It gives the best placement of temperature sensors to estimate the temperature induced deflections and is capable of reconstructing the data with high accuracy.

  • 15. Uhlmann, Eckart
    et al.
    Saoji, Mihir
    Peukert, Bernd
    Technical University of Berlin.
    Principles for the Interconnection of Modular Machine Tools2016In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 40, p. 413-418Article in journal (Refereed)
    Abstract [en]

    An approach for reusable and adaptable machine tool frames is the modularization of the frame structure by breakdown to hexagonal primitives. The design of small light weight modules allows for the assembly of a high variation of different geometries and enables scalable structures. However, a core issue in designing modular products is the proper definition of interfaces within the own product family and the outside, by which the usability and flexibility of the modular structure is mainly influenced. In the context of modular machine tool frames, conventional mechanical criteria like stiffness, reliability and cost are key factors when designing new joining techniques. Taking sustainability into account, additional aspects of social, economic and ecologic dimension become important. This paper presents a study on reusable connection principles for modular machine tool frames and gives an evaluation according to sustainability criteria by using a fuzzy analytical network process.

  • 16. Uhlmann, Eckart
    et al.
    Saoji, Mihir
    Peukert, Bernd
    Technical University of Berlin.
    Utilization of thermal energy to compensate quasi-static deformations in modular machine tool frames2016In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 40, p. 1-6Article in journal (Refereed)
    Abstract [en]

    One functional requirement of machine tool frames is to maintain relative geometric positioning of interfaces irrespective of any surrounding effects or conditions. Challenges for the absolute accuracy of axis positioning are quasi-static deformations in machine tool structures due to temperature variations caused by environment or the manufacturing process. On the advent of increased research in solid state materials for thermoelectric modules, the utilization of thermal energy as a beneficial source needs to be evaluated. This paper presents the conceptual design of a thermally actuated module which can compensate the previously mentioned quasi-static deformations in the framework of a building set for modular machine tool structures. The principle of different thermal expansion coefficients of materials is exploited in the design of the module to facilitate a compensating movement. The module works energy autarkic as well as controlled by external energy input.

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