Scalable Process Chain for Flexible Production of Metal-Plastic Lightweight Structures

Dröder, Klaus; Reichler, Ann-Kathrin; Mahlfeld, Georg; Droß, Marcel; Gerbers, Roman

doi:10.1016/j.procir.2019.09.045

Cited by 8 publications

(5 citation statements)

References 11 publications

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“…This study focused on the generation of structural polymer-aluminum joints by means of ME. Based on the relevant literature [3,[19][20][21][22][23][24], the following questions arose:…”

Section: Discussionmentioning

confidence: 99%

“…In our previous work [24], we showed the ability of thermographic process monitoring to characterize the ME joining process in terms of wetting and joint strength, as exemplified by poly(lactic acid) (PLA)-aluminum joints. While Herlte et al [22], Dröder et al [23] and Bechtel et al [24] observed a large influence due to substrate temperature, T s , Falck et al [19] reported only a minor effect. As Falck et al applied a primer beforehand, the polymer was not deposited directly on the metal surface during the ME process.…”

Section: Introductionmentioning

confidence: 96%

“…The increased contact temperature resulted in improved filling of the microstructures of the electrochemically treated aluminum surface. Dröder et al [23] joined ABS to surface structured aluminum substrates. Higher surface structures and substrate temperatures resulted in increased tensile single-lap-shear strength.…”

Section: Introductionmentioning

confidence: 99%

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Material Extrusion of Structural Polymer–Aluminum Joints—Examining Shear Strength, Wetting, Polymer Melt Rheology and Aging

et al. 2022

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Generating polymer–metal structures by means of additive manufacturing offers huge potential for customized, sustainable and lightweight solutions. However, challenges exist, primarily with regard to reliability and reproducibility of the additively generated joints. In this study, the polymers ABS, PETG and PLA, which are common in material extrusion, were joined to grit-blasted aluminum substrates. Temperature dependence of polymer melt rheology, wetting and tensile single-lap-shear strength were examined in order to obtain appropriate thermal processing conditions. Joints with high adhesive strength in the fresh state were aged for up to 100 days in two different moderate environments. For the given conditions, PETG was most suitable for generating structural joints. Contrary to PETG, ABS–aluminum joints in the fresh state as well as PLA–aluminum joints in the aged state did not meet the demands of a structural joint. For the considered polymers and processing conditions, this study implies that the suitability of a polymer and a thermal processing condition to form a polymer–aluminum joint by material extrusion can be evaluated based on the polymer’s rheological properties. Moreover, wetting experiments improved estimation of the resulting tensile single-lap-shear strength.

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“…This study focused on the generation of structural polymer-aluminum joints by means of ME. Based on the relevant literature [3,[19][20][21][22][23][24], the following questions arose:…”

Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 96%

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Material Extrusion of Structural Polymer–Aluminum Joints—Examining Shear Strength, Wetting, Polymer Melt Rheology and Aging

et al. 2022

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“…Based on the assessment of the assembly stages involving human labor, it has been determined that certain processes, namely material preparation, assembly, and processing, pose significant risks to workers and require intensive labor efforts [23]. To address these challenges and improve overall efficiency and safety, the prototype incorporates full automation of these critical processes.…”

Section: Production Processesmentioning

confidence: 99%

Prototype for the Application of Production of Heavy Steel Structures

Bulganbayev,

Suliyev,

Fonseca Ferreira

2024

Electronics

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This study provides a comprehensive overview of the automated assembly process of large-scale metal structures using industrial robots. Our research reveals that the utilization of industrial robots significantly enhances precision, speed, and cost-effectiveness in the assembly process. The main findings suggest that integrating industrial robots in metal structure assembly holds substantial promise for optimizing manufacturing processes and elevating the quality of the final products. Additionally, the research demonstrates that robotic automation in assembly operations can lead to significant improvements in resource utilization and operational consistency. This automation also offers a viable solution to the challenges of manual labor shortages and ensures a higher standard of safety and accuracy in the manufacturing environment.

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“…As an example, this can be done by choosing a suitable vacuum gripper size for the accessible object surface or adapting gripper fingers of mechanical grippers to the object contours [1]. For industrial applications with shortening development cycles of new product variants and sometimes even overlapping transitions between product generations, solutions for a multifunctional, flexible handling or gripping of different components are required [2]. According to Hesse [3], three different types of flexibility for automated hand-ling processes can be defined:…”

Section: Introduction -Challenges For Universal Handlingmentioning

confidence: 99%

Empirically adapted model for the Handling of Variable Geometries with Vacuum-based Granulate Grippers

Wacker¹,

Dierks²

2022

Preprint

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<p> Current industrial trends show an increasing demand for individualized products, which require highly flexible yet automated production systems. Universal handling systems offer an efficient solution for the flexible and safe handling of differing component geometries and shapes. An innovative gripper for form-flexible handling combining vacuum systems with the flexibility of granulate grippers was established in previous research and has continued to prove its flexibility by gripping wide varieties of object geometries. The current challenge of modelling and predicting gripping forces for this new gripper is addressed in this research. Multiple object geometries are selected and examined, with the parameters affecting the air permeability being the most important influence for the gripping forces. Along with an overview of influencing factors and parameters, a framework for a linear model enabling the prediction of gripping forces for different object shapes is developed. The basis for automated prediction of gripping strengths for different types of objects is established with this research and could be adapted with other, non-analytical models such as machine learning in the future. </p>

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Scalable Process Chain for Flexible Production of Metal-Plastic Lightweight Structures

Cited by 8 publications

References 11 publications

Material Extrusion of Structural Polymer–Aluminum Joints—Examining Shear Strength, Wetting, Polymer Melt Rheology and Aging

Material Extrusion of Structural Polymer–Aluminum Joints—Examining Shear Strength, Wetting, Polymer Melt Rheology and Aging

Prototype for the Application of Production of Heavy Steel Structures

Empirically adapted model for the Handling of Variable Geometries with Vacuum-based Granulate Grippers

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