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© Fraunhofer IWU
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Research on Key Enabling Technologies
at Fraunhofer IWU
Bozen, 27. März 2015
© Fraunhofer IWU
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Curriculum Vitae Personal Data
Surname:
First Name:
Date of birth:
Place of birth:
Family status:
Education and Work Experience
Kunze
Holger
06.12.1971
Eilenburg (Sachsen)
married
09/1990 – 04/1996
05/1996 – 12/2001
01/2002 – 12/2004
01/2005 – 12/2010
since 01/2011
Study at Friedrich-Schiller-Universität Jena Field: Electrical engineering, Degree: Dipl.-Ing.
Research Assistant at Group-Research VW Wolfsburg Topics: New materials/Smart materials
Scientist at Fraunhofer IWU Dresden Position: GL Multi-functional materials
Head of Department Adaptronics and Acoustics at IWU Position: AL Adaptronics und Acoustics
Division Director Mechatronics and Lightweight Structures
© Fraunhofer IWU
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CONTENT
The Fraunhofer-Gesellschaft / The Fraunhofer IWU
Leading Projects
E³-Research Factory
smart³
Key Enabling Technologies – Production engineering
Adaptronics – smart materials – application examples
Metal Foam
Additive Manufacturing
Networking with SME’s
© Fraunhofer IWU
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The Fraunhofer-Gesellschaft at a Glance
Applied research for immediate utility of economy and benefit of society
More than
24 000 staff
roughly 70% are
generated through
contract research on
behalf of industry and
publicly funded
research projects
roughly 30% are
contributed by the
German federal and
Länder governments
67 Institutes and
research units
Researc
h v
olu
me
€2 billion
2014
Contr
act
researc
h
€1,7 billion
© Fraunhofer IWU
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Fraunhofer worldwide
Dubai
Bangalore
Jakarta
Peking Seoul
Tokio
Boston
Plymouth
East
Lansing San José
Newark Maryland
Kairo
Ampang
Santiago de Chile
Singapur
Cambridg
e
Brüsse
l
Porto
Wien
Bozen Graz Budapest
Wrocław
Göteborg
Thessaloniki
Sydney
Londo
n
Glasgow
Salvador
Sendai
Paris
São Paulo
Campinas
Vancouver
Southampton
Jerusalem
Stellenbosch
Storrs
Joint Lab
Fraunhofer IWU /
Stellenbosch University
Joint Lab
Fraunhofer IWU /
University
Napels
Federico II
Subsidiary
Center
Project Center
ICON / Strategic Cooperation
Representative / Marketing Office
Senior Advisor
© Fraunhofer
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Fraunhofer-Niederlassungen und deren Center weltweit
Fraunhofer Austria Geschäftsbereich Produktions- und
Logistikmanagement, Wien
Geschäftsbereich Visual Computing, Graz
Fraunhofer Italia Fraunhofer Innovation Engineering Center IEC,
Bozen
Fraunhofer Portugal Fraunhofer Center for Assistive Information and
Communication Solutions AICOS, Porto
Fraunhofer Schweden Fraunhofer-Chalmers Research Center for
Industrial Mathematics FCC, Göteborg
Fraunhofer UK Fraunhofer Centre for Applied Photonics CAP,
Glasgow
Fraunhofer USA Fraunhofer Center for Coatings and Diamond
Technologies CCD, East Lansing
Fraunhofer Center for Experimental Software
Engineering CESE, Maryland
Fraunhofer Center for Laser Applications CLA,
Plymouth
Fraunhofer Center for Manufacturing Innovation
CMI, Boston
Fraunhofer Center for Molecular Biotechnology
CMB, Newark
Fraunhofer Center for Sustainable Energy
Systems CSE, Cambridge
Fraunhofer Center for Energy Innovation CEI,
Storrs
Fraunhofer Chile Fraunhofer Center for Systems Biotechnology,
Santiago de Chile
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Industry in Saxony
Dresden
More than 536,000 inhabitants
Hi-tech location with the key technologies:
Micro/nanoelectronics / information- and communication technology
New materials / Nanotechnology / photonics
Life science / biotechnology
Top center for research in Germany: e.g. “excellence university“
TU Dresden, 10 Hochschulen, 11 institutes and research units of the
Fraunhofer-Gesellschaft, 3 Max-Planck-Institutes, 3 Leibniz-Institutes
© Dresden Marketing GmbH
© Fraunhofer IWU
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Industry in Saxony
Autoland Saxony
3 vehicle manufacturers (OEMs):
Volkswagen (three production sites)
as well as Porsche and BMW
More than 750 suppliers,
service providers and equipment
providers
More than 70,000 employees in the
automotive supply industry
© iStockphoto
© Fraunhofer IWU
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Industry in Saxony
Mechanical and Plant Engineering
Cradle of Machine building
largest center of mechanical
engineering in East Germany with
more than 100 SMEs in Chemnitz
and more than 500 in the region
high concentration of companies
(machine tools, special
engineering and automation)
© Fraunhofer IWU
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THE FRAUNHOFER IWU
Strategy “Resource-efficient production“
© Fraunhofer IWU
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Research under the heading “Resource-efficient Production“
The Fraunhofer IWU in Profile
Scientific fields
Mechatronics and lightweight structures
Machine tools and production systems
Forming technology and joining
Machining
founded in 1991
about 590 employees
€37.6 million annual budget
locations in Chemnitz, Dresden,
Augsburg, Zittau and Wolfsburg
© Fraunhofer IWU
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IWU-Strategy “Resource-efficient production“
Leading projects
Fraunhofer IWU
E³-Research Factory
Resource-efficient
Production
Excellence Center
Automobile
Production
Fraunhofer
Lighthouse Project
E3-Production
smart3
3Dsensation
Additive
Manufacturing
E³-Research Factory
FoFaB-K
BMBF-Program
Twenty20
Partnership for
Innovation
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Maxim: towards the Factory of the Future -
Solutions for the production technology of
tomorrow
E³-Factory:
Energy- and resource-Efficient production
Emission neutral factory
Human Embedding into production
Competence areas:
Powertrain
Body shop
Energy management 2.0
Partners:
VW, AUDI
KUKA, PhönixContact
Leading project
E³-Research Factory
Resource-efficient Production
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Function and structure are
separated
Excl. weight / space reduced
Fusion of function and
structure
shape-memory
vision
electromagnetic actuator
Objective : Development of marketable smart
materials and components
Consortium consists of 60 partners, including 46
SMEs
Term: 6 years (2013 – 2019)
Total funding: €45 million
General management : Fraunhofer IWU
Leading project
smart³
© Fraunhofer IWU
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Leading project
smart³
A Network Approach
Conventional:
Bring people together without breaking up borders between the disciplines
> Low Innovation
Smart Approach:
Cross-border Integration
> High Innovation
© Fraunhofer IWU
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Leading project
smart³
> 13 % pro Jahr
Our Vision on the Way
© Fraunhofer IWU
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Leading project
smart³
> 13 % pro Jahr
© Fraunhofer IWU
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Key Enabling Technology – KET
ADAPTRONICS
© Fraunhofer IWU
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Smart Materials – the basis for ADAPTRONICS
An overview
Smart materials are materials that have one or more properties that can be
significantly changed in a controlled fashion by external stimulation, such as
stress, temperature, moisture, pH, electric or magnetic fields.
Activation fields
Electrical field
Magnetic field
Temperature
Light
...
Material property
geometry
stiffness
viscosity
Electrical resistance
Heat conductivity
...
actuator
sensor
Development of solid-state actuators
Multi-functional Material is sensor an actuator in one element
Actuator characterization by reachable stress and strain scaling by length and
cross-section of material
© Fraunhofer IWU
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Smart Materials
An overview
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Materials, Basics, Applications
Piezoceramics
Direct Effect
Sensor Mode
V
+
-
L
(b) indirekter
Effekt
V
+
-
L
(b) indirekter
Effekt
-High blocking forces (100N/mm2)
- Small strains (0,2%)
- Very high actuation frequency (>100kHz)
Fuel-Injektor Flexible Patch-Actuator
Mechanism:
Deformation of dipoles in the chrystal
creates a dislocation of charge carriers
electrical voltage
indirect Effect
actuator Mode
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Auslegung und Konstruktion des
adaptronischen Werkzeugsystems
10 µm
Deformat ion
- oben -
Deformat ion
- Mit te -
Piezo-actuators
Tool Center
Point
Spindle
Target Contour
Adaptronic Tool
System
Machined Contour
Motivation:
Extending limits of manu-
facturing processes to open
new design possibilities
Manufacturing of micro
contours and micro structures
Concept:
High precision by means of
piezo-based sub-kinematics
Active control of cutting edge
Materials, Basics, Applications
Piezoceramics – Application Example Tool Positioning
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Status Quo: Drive tests:
Noise reduction of
12 dB at 210 Hz
Motivation:
Improving the acoustic behaviour of
lightweight automotive components
Concept:
Integration of piezoceramic-actuators
in automotive drive shafts
Experimental analysis: Problem
first bending mode of drive shaft at 210Hz
Application/Integration (FRP) of Piezo-
Patch-Actuators
System and control
design
Materials, Basics, Applications
Piezoceramics – Application Example Vibration
Reduction
© Fraunhofer IWU
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Materials, Basics, Applications
Shape Memory Alloys
T>Af
T<Ms
freier Aktor
Aktor gegen Feder
blo
ckie
rter A
kto
r
SM-Actuators made of
different semi-finished
product
- High strains (5 %)
- Very high Blocking Forces: 350 N/mm2
- Low actuation frequency: <1Hz
- Excellent spezific workload Miniaturization
Stress-Strain-Behavior
Source: Alfmeier
specific workload [J/cm3]
Drive for pneumatic
valves in automotive
seats
Mechanism:
Thermal induced Phase Transformation of NiTi changes the
lattice structure (Martensite Austenit)
changing of stress-strain behavior
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Task: Releasing petrol cap
Benefits: Lightweight design, cross section
Drive characteristics: Fast switching
Drive parameters:
Reset by spring
Force: 10 N Diameter: 0,3mm
Deflection: 5 mm Length: 120mm
Petrol cap release device
Parameter Electric Drive SMA-Drive
Weight 104 g 10 g
Number of
parts 10 3
Cross section see figure see figure
SMA-Drive completely noiseless
SMA-drive
Electric drive with gear head
Materials, Basics, Applications
Shape Memory Alloys – Application Example Petrol Cap
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Conventional connector
Thermal picture of a loosen connector
SMA connector
Materials, Basics, Applications
Shape Memory Alloys – Application
Example Electrical Connector
In electrical engineering connectors are commonly
used for connecting and releasing electrical
conductors
if contact force decreases the conductor can
become loose
current density increases
exceeding heat in the clamp area
Solution: Integration of SMA-Element
in the conmnector
Arising heat causes geometry change of the SMA
Elementes
Actuation of force resets the contact and resistance
decreases
© Fraunhofer IWU
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Materials, Basics, Applications
Shape Memory Alloys – Application Example Oxygen Mask
Specifications of solenoid:
Weight: 82 g
Dimension: 21 cm³
Power input: 11 W
Number of elements: 30
Releasing device for oxygen masks: solenoid – device with SMA – vision: integrated SMA-actuator
Specifications of SMA system:
Weigth: 10g (-88%)
Dimension: 4cm³ (-80%)
Power input 1,8W (-84%)
Number of elements: 5 (-83%)
Example A380 (600 oxygen masks) → possible weight reduction of 43 kg per flight
© Fraunhofer IWU
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Materials, Basics, Applications
Electroactive Polymers
- Very high strains (10 %)
- Medium blocking Forces: 0,1 N/mm2
- High actuation frequency: >1kHz
- Excellent efficiency, excellent specific workload
Mechanism:
actuation caused by electrostatic forces between two
electrodes squeeze the polymer
compression in thickness and Expansion in width
Buckling EAP Actuator EAP Loudspeaker EAP driven airship
© Fraunhofer IWU
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Materials, Basics, Applications
Electroactive Polymers – Applications
Energy Harvesting:
EAP energy harvesting in shoes EAP ocean wave generator
© Fraunhofer IWU
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Key Enabling Technology – KET
METAL FOAM
© Fraunhofer IWU
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PARTS made of METAL FOAM
Al-Schaum
Al – Al-Schaum – Sandwich bis ca. 2.500 x 1.250 mm2
Zn-Schaum
3-D-Formteile
ausgeschäumte Stahlprofile
Stahl – Al-Schaum – Sandwich (bis ca. 1.800 x 1.400
mm2)
Metallschaum- und Sandwichplatten mit Metallschaum
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5900 mm
1400 m
m
940 mm
Stahl-Aluminiumschaum-Sandwiches
1 178 x 1 182 x 35
Stahl / Al-Schaum / Stahl – 3 / 29 / 3
Application Example: Crossbar of a Milling Machine
Stahl-Aluminiumschaum-Sandwich + kohlefaserverstärkte Kunststoffe
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Key Enabling Technology – KET
ADDITIVE MANUFACTORING
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Metal
Laser Beam Melting
Plastics
3D-Printing
Fused Layer Modeling (FLM/FDM)
Selective Laser Sintering (SLS)
M2 Cusing (Concept Laser),
IWU, Dresden SLM Realizer 100 (Realizer),
IWU, Dresden
SLM 250HL (SLM Solutions),
Augsburg, RMV
FORTUS 900mc
(Stratasys),
Bautzen / Zittau
Dimension SST Delta Tower
1200es (Stratasys), TU Chemnitz,
IWP (RP-Laboratory)
Cube X (3D
Systems),
Chemnitz
ZPrinter 310 + Zprinter 450
(3D Systems / Z Corp.),
TU Chemnitz,
IWP (RP-Labor)
SLM 250HL (SLM Solutions),
TU Chemnitz, SLK
sPro™60 HD-HS
High Speed SLS® Center (3D Systems)
Zittau
Additive Manufacturing at the Fraunhofer IWU
Overview
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Principle sketch of a laser melting machine
direct, single step process, creating
parts out of series-like metallic material
complete local melting of the metal
powder to a 99.5 - 100 % dense
microstructure
Schematic diagram of Selective Laser Melting
LASER BEAM MELTING at the Fraunhofer IWU
Process
© Fraunhofer IWU
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LASER BEAM MELTING at the Fraunhofer IWU
Fields of work – Tool making (Conformal Cooling)
Plastic Injection Molding
(customer: IAT Stellenbosch)
High Pressure Die Casting
(customer: DGH Group) Press Hardening
(customer: Volkswagen)
Die Forging (customer:
Mahindra Forgings Europe)
Development and design of innovative, conformal mold and tool temperature control
systems
Support with the complete tool design, distinctive design of active components for Laser
Beam Melting
Additive manufacturing of mold and tool inserts by Laser Beam Melting
Support of production start-up and process monitoring
Evaluation of additively manufactured components compared to conventionally
manufactured tool
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Development, design and manufacturing of instruments, devices and patient-specific
implants
Functional integration (surface / volume structures, channels and cavities)
Feasibility studies for medicinal applications
LASER BEAM MELTING at the Fraunhofer IWU
Fields of work – Medical technologies
© Fraunhofer IWU
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LASER BEAM MELTING at the Fraunhofer IWU
Fields of work – Components (Rapid Manufacturing)
Rapid Prototypes in standard metallic material with
series like properties
Direct Rapid Manufacturing of components for series
production (motorsports, medical technology etc.)
Development, design and production of new
lightweight components with lattice or bionic structure
for applications in mechanical and aerospace
engineering etc.
© Fraunhofer IWU
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THE FRAUNHOFER IWU
Networking with regional partners
© Fraunhofer IWU
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Example for Networking with SME‘s: POLY-LAB.NET
Building the network
Started with 10 members; actual 15 members
Building homepage www.poly-lab.net
PR-work (TV, newspapers, journals etc.)
Trade fairs (Fakuma, eCarTec, Materialica, Agritechnica)
© Fraunhofer IWU
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POLY-LAB.NET
Building KULAN step by step
© Fraunhofer IWU
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POLY-LAB.NET – Implementation
Demonstration-Car KULAN
technical data:
Mass 300 kg, vehicle payload max. 1000 kg
Range about 300 km at a topspeed of 50 km/h
Currently 2 wheel hub motors with a power of 2 kW in the back tires
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POLY-LAB.NET - Impressions
Demonstration-Car for ecological farming
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Thank you !
Contact: Dipl.-Ing. Holger Kunze
Fraunhofer IWU Dresden
Tel. +49 351 4772 2520
