(Fraunhofer Society for applied Research) The Fraunhofer Organisation
• Was founded in 1949 and is recognized as a non-profit organisation • The leading organisation of applied research in Germany • 58 research institutes in Germany • About 12,000 employees , about the half of them scientists and engineers • Annual research budget >1 billion € • Affiliated research centres and representative offices in Europe, the USA and Asia • Headquarter of the The organization takes its name from Joseph von Fraunhofer (1787-1826) , Fraunhofer-Gesellschaft is in Munich the illustrious Munich researcher, inventor and entrepreneur
2 The Fraunhofer-Gesellschaft in Germany
Itzehoe 58 Institutes at 40 Locations Bremen Hannover ~ 12 000 Employees Berlin Braunschweig Golm Oberhausen Magdeburg ~ 1 Billion € Budget per Year Dortmund Duisburg Schmallenberg St. Augustin Leipzig Dresden Aachen Jena Euskirchen Chemnitz Ilmenau Darmstadt Würzburg
Kaiserslautern Erlangen St. Ingbert Saarbrücken Pfinztal Karlsruhe Stuttgart Freising Freiburg
3 The Profile of the Fraunhofer-Gesellschaft
7 Alliances Alliance Production (founded 1998) Micro Electronics Production IPT Aachen IPK Berlin Information and Communication IWU Chemnitz Material and Components IML Dortmund IWU Dresden Life Sciences IFF Magdeburg Surface Technology and Photonics IUSE Oberhausen Defence and Security IPA Stuttgart TEG Stuttgart
4 Fraunhofer Institute for Machine Tools and Forming Technology Fraunhofer-Institute for Machine Tools and Forming Technology
Chemnitz In Numbers : Focus : 170 researchers Machine Tools and engineers Mechatronics 130 students Forming Technologies and trainees Precision Engineering 16 Mio. € budget in Chemnitz und Dresden
Networks :
Dresden Fraunhofer-Gesellschaft (58 institutes of applied research) Universities in Saxony, Germany Dresden and worldwide Chemnitz Automotive industry (OEMs) and suppliers German and European Machine Tool Producers
6 Core Competences
Technologies Machines and for Automotive Components Components
Precision in Micro Integration of IC Technologies Mechatronics und Macro into Production Engineering
7 Organizational Structure and Regional Networks
Fraunhofer Institute Machine Tools and Forming Technology (IWU) Machine Tools Cutting Forming and Production Mechatronics Techniques Technology Systems Production System Cutting Sheet Metal Systems Techniques Technologies Forming
High-Precision Adaptronic Bulk Metal Machine Tools and Micro Applications Forming Fabrication DFG-Transfer- bereich 50 Prototypes / Joining SFB 457
Regional Production Networks
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8 Innovation Platforms of the Fraunhofer IWU
Research for the Innovative Cluster Saxon economy Mechatronic Engineering
VEMAS VEMAS Research initiatives and programs NEMO NEMO Precision Casting Hydroforming
MAINE MAINE Phase 1 Phase 2
KMC KMC+ KMC++ complete machining platform strategies industrial engineering KMC
1997 19981999 20002001 20022003 2004 2005 2006 2007 2008
9 R&D-Cluster Machine Tool Manufacture
The Saxon Machine Tool Industry Alliance Chemnitz - KMC
Research projects
Project phase 1 „Process combination and complete machining“ 09/1998 till 12/2000 six joint projects with more than 30 participating companies and R&D institutions total volume: 21,5 million € >> circa 84 million € sales increase >> 16 patents
Project phase 2 „Platform concepts for mechanical engineering“ 03/2001 till 12/2003 five joint projects with more than 30 participating companies and R&D institutions total volume: 20,5 million € >> ca. 77 million € sales increase >> 15 patents
Project phase 3 „Technologies in mechanical engineering for industrial engineering, starting 2004/2005 construction and infrastructure“
10 Mechanical Engineering Initiative Next Economy
Project partners Leaded by the Volkswagen Sachsen GmbH and coordinated by the Fraunhofer IWU more than twenty companies (Suppliers to ThyssenKrupp Drauz automotive industry and machine tool builders) were involved in Preßwerk the collaborative project with a total budget of Hydroforming about 28 Mio. €.
Phase I: 2002 – 2005, supported by Saxon Ministry of Economy
11 Innovative platform for mechanical and automotive engineering
Mechanical Engineering Initiative Next Economy MAINE – Phase I
“Fully automated laser welded car body “Residue-free engine manufacturing” manufacturing”
II original and forming III optimized deep I burr- and chip-free technologies drawing parts IV Laser process manufacturing for avoidance of made of forming and in car body of engine components residues joining methods manufacturing
assembled Online-control of the crank shaft laser process for an optimal welded seam New boring tools with optimal chip formation, Demonstrator part decuple lifetime increase „B-pillar Golf 5“ resulting from coatings 3 manufacturing concepts
Improvement Quantum jump Quantum jump Improvement
12 Crank Shafts
hollow big end Process Chain: bearing - force fitting / welding bearing (longitudinal - surface grinding of cheek cheek big end pressing, - joining complete shaft with cheek-cheek bearing laser welding) (precision cut, - grinding complete shaft 100% flush-cut) Advantages: • approx. 25 % weight savings against serial shaft • high flexibility by modular assembly • extension of constructive possibilities (material versions , location and construction of oil well )
hollow cheek Project Results: main main bearing bearing (precision cut • test of first prototypes in „lighted“ motor as well as in 100% flush-cut) the vehicle have been done successfully Construction of a crank • testing of prototypes on the vibration test rig of the manufactured crank-shaft (bending and torsion) and further optimization of fatigue strength
13 B-Pillars Benchmarking of three strategies for the production of a B-pillar
Criterions
Production - Costs for equipment and tools - Material - Cycle time Double Sheet Hydroforming Hydroforming of a tube Component Properties (especially stiffness ) Deep Drawing
Technological Variants
Conventional deep drawing
Double Sheet Hydroforming (inner and outer part of the B-pillar)
Hydroforming of a tube
14 Machine System Design and Process Development
StarragHeckert machine concept 2-spindles- machine with linear motors for dry machining
New Machine Systems WEMA Vogtland Application of the demonstrator modules to the dry machining at a “round step machine” + NILES-Simmons machine concept for the HOHENSTEIN ortogonal turn milling of Intelligent hardened crank-shafts clamping device
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