Conference Program

April 12, 2010 and April 13, 2010

The conference language is English.

First Conference Day – April 12, 2010, Monday

09:00
Welcoming Address
Prof. Ursula Gather
Rector of the Technische Universität Dortmund
09:15
Opening Speech
Prof. Peter Grünberg, Nobel Prize Laureate in Physics 2007
Forschungszentrum Jülich
09:55
The Next Frontier in Industrial Energy Efficiency
Prof. Ernst Worrell, Nobel Peace Prize Laureate 2007
Utrecht University, The Netherlands
Industry contributes directly and indirectly (through consumed electricity) about 37% of the global greenhouse gas emissions, of which over 80% is from energy use. Total energy-related emissions, which were 9.9 GtCO₂ in 2004, have grown by 65% since 1971. In the near future, energy efficiency is potentially the most important and cost-effective means for mitigating greenhouse gas emissions from industry. Despite the growth in energy use, industry has almost continuously improved its energy efficiency over the past decades. Yet, climate change and other future challenges will drive a quest for further energy-efficiency improvement. Both improvements with which industrial processes use energy and materials are key to realize strong reductions energy use. This paper discusses the potential contribution of industrial energy and material efficiency technologies to reduce energy use and greenhouse gas emissions to 2030 and beyond, and ways to realize them.
10:35
Coffee break
11:00
New Directions for Manufacturing Engineering – An Energy and Environmental Perspective
Prof. Gerald Byrne*, Dr. Eamonn Ahearne
President CIRP
University of Dublin, Ireland
As the dominant paradigm for improving general living standards since the first industrial revolution, “economic development (ED)” is now regarded as unsustainable in view of the depletion of natural resources, pollution, destruction of eco-systems and CO₂ emissions related to climate change and global warming. The alternative paradigm, referred to as “sustainable development (SD)”, demands a global approach and both “top-down” and “bottom-up” actions. The SD paradigm will be enabled by the paradigm “competitive sustainable manufacturing (CSM)” which requires new business models that deliver a product-service, provide a return to the business and are carbon-neutral and environmentally benign.
The role of the Manufacturing Engineer will change under the CSM paradigm, and this is being informed by research in networks such as CIRP, the International Academy for Production Engineering. Manufacturing Engineers involved in “new product introduction” and “supply chain” processes will have a particular responsibility for new “key performance indicators” such as the “embodied energy” in the product-service over multiple life cycles. In the context of the life cycle model for embodied energy, the energy efficiency of defined and undefined edge cutting processes is considered in general terms. By “following the energy”, some fundamental questions are posed. It is noted however that “total life cycle embodied energy” must be considered since functional specifications determined by the manufacturing process (dimensional tolerances, levels of surface finish and integrity) may affect embodied energy in other life cycle phases.
11:40
Manufacturing-related product properties: challenges and changes
Prof. Fritz Klocke* et al.
Past President CIRP
RWTH Aachen
The manufacturing of highly innovative products requires a target-orientated technology application in order to induce specific manufacturing-related product properties. These products provide a competitive advantage for the western industrial nations towards emerging countries due to their differentiation in contrast to budget-priced products. The manufacturing process of highly innovative products is accompanied by time- and cost-intensive pilot test due to a necessary process calibration. The reasons for this inefficient process design are non or only partly existent process models. This knowledge gap prevents a target-oriented generation of manufacturing-related product properties. A chronological development of process models is presented for different manufacturing technologies. Advances in terms of modeling, achievable accuracies as well as optimization capabilities are described for process models of different manufacturing technologies. Aside from the process modeling, further challenges regarding the topic of manufacturing-related product properties are identified.
12:20
Lunch
14:00
Microstructure-Property Relations in Materials and Components – New Methods for non-destructive and in-situ Characterizations
Prof. Anke Kaysser-Pyzalla*, Prof. John Banhart
Helmholtz-Zentrum Berlin für Materialien und Energie
14:40
Multiscale Material Modelling
Prof. Andreas Menzel* et al.
TU Dortmund
Multiscale material modelling constitutes one of the key multidisciplinary research lines in the field of applied mechanics, applied mathematics, and material sciences. Apart from developing efficient computational frameworks that appropriately recapture the relevant micromechanical properties of a material and additionally enable to transfer these to the macroscopically observed material behaviour, a long term goal consists in making these formulations also available to the simulation of technologically relevant production processes. In this regard, four different modelling approaches are reviewed in this contribution, whereby two of these focus on the modelling of shearband formation, while the remaining two make use of so-called laminate theories applied to a homogenization problem and the simulation of phase-transformation phenomena.
15:20
The Role of Manufacturing Process in the Design for Product Risk
Prof. Rajiv Shivpuri*, Kuldeep Agarwal
The Ohio State University, USA
High societal risks are associated with the failure of manufactured products but their processing history is often ignored in the product design and failure analysis. It is assumed that safe life approach will cover for inhomogeneity and randomness in material state and that the multistep manufacturing route can be designed by optimizing shape and property at each individual step. The result of these assumptions has often been unintended catastrophic failure of product in service. This paper presents a computational approach to examine the role of manufacturing defects and their evolution on the product life. Focus is on melting related defects that often lead to in-flight failure of aeroengine disks made from titanium alloys. Two types of defects are considered in the titanium matrix, high-severity/ low-occurrence defect such as hard alpha and high-occurrence/low-severity high density inclusions. While the low-frequency hard alpha is modeled using a multi-body approach in the FEM formulation, high frequency second phase particles are modeled as clusters that move with meal flow. These models are used to study the influence of processing conditions such forging temperatures and die velocities, and perform design on the deformation and locations of these defects in the finisher forging, and the effect of this transformation on the severity of failure. These deterministic results are converted into risk factors using convergent zone method. It is shown that risk based design of material processing is critical for increased reliability in product realization.
16:00
Coffee break
16:20
Efficient Use of Resources in Machining – Challenges to a Global Player in Production
Dr. Sellal Mussa*, Martin Lenzer
Bosch Rexroth AG
Today, an efficient use of resources is growing more and more important in manufacturing systems. With increasing prices for resources an efficient production is becoming an actual competitive factor. Bosch Rexroth provides the 4EE systematic (Rexroth for Energy Efficiency) which is based on four fundamental levers to increase the energy efficiency in the manufacturing process: Efficient Components, Energy Recovery, Energy on Demand, Energy System Design. The 4EE systematic and approach are evaluated and implemented at different Bosch Rexroth plants. The four levers are a useful base for an effective increase in the energy efficiency of production machines. As a result up to 35% of reduction in energy consumption could be achieved by applying 4EE to different machining centres.
17:00
Tailor Made Properties – Visions for the Future of Manufacturing
Prof. A. Erman Tekkaya*, Prof. Dirk Biermann, Prof. Wolfgang Tillmann
TU Dortmund
Classical product design process does not consider the manufacturing process in specifying the material ability. Products are validated by physical tests checking failure but not overdesign. Therefore, all products are currently oversafe. This leads to more material and more energy investment. A paradigm change is necessary to save energy in design of products by considering manufacturing effects. A further step leads to “tailored” products with local deterministic and optimized properties. This paper describes this paradigm change in design and manufacturing of products and gives the first examples of application for this sound approach.
19:30
Social Dinner
Deutsche Arbeitsschutzausstellung (DASA)
Friedrich-Henkel-Weg 1-25
44149 Dortmund
[Homepage]

Second Conference Day – April 13, 2010, Tuesday

08:30
Production of Magnesium Implants with Adapted Properties
Prof. Friedrich-Wilhelm Bach*, Dr. Dirk Bormann
Leibniz Universität Hannover
Over the past years, increased interest has developed in new types of implant materials for biomedical engineering. Both, the investigation and characterization of biodegradable materials, such as magnesium, were brought into focus to reduce post-operative procedures in future. Here, it appears advantageous to obtain complete knowledge about effects and parameters occurring within the process chain of these implant materials, to have the chance, to influence the implants final mechanical and corrosive characteristics. Therefore, the analysis of the pre-operative basic conditions as well as the analysis of the desired process chain is necessary. Especially, Casting, Hot Extruding, Coating and Sterilization methods provide numerous controllable and unintentional effects which must be made accessible to enable conclusions to be made about the magnesium alloy’s potential field of application.
09:10
Fundamental Understanding of Materials Joining Technologies for Optimizing Joint/Component Soundness and Performance
Prof. J. Ernesto Indacochea*, Dr. Stephen Liu
University of Illinois at Chicago, USA
Joining technologies are essential for the manufacturing of most products. Yet, these processes often appear to generate more of the production difficulties than might be predictable. This manuscript addresses some complex materials issues and processing concerns related weld development in fusion welding. It provides a fundamental and scientific assessment on property prediction of weld joint. A review is offered of the favorable weld microstructures in high strength steel welds and the metallurgical and processing factors that promote their development. A mathematical formulation that encompasses these interrelated factors is suggested in order to predict a weld property, but its limitations are addressed due to the quickness of the process and complex solidification issues. It is found that the disparity of properties in short distances is so random that a clear explanation or property prediction based on fundamental Materials Science is quite difficult and uncertain. In other words the prediction of the steel weld microstructure and properties may only be possible through the combined applications of non-uniform Materials Science (deterministic approach) and advanced analytical methodologies (i.e. artificial intelligence and neural network). However the challenge remains to more accurately predict the outcome of the weld, by developing a mathematical expression that takes into consideration the processing weld parameters, metallurgical factors, and property variability of the different components to predict the final weld property.
09:50
Prediction of coating's properties after micro-blasting and their effect on the tool's cutting performance
Prof. Konstantinos-Dionysios Bouzakis* et al.
Aristoteles University of Thessaloniki, Greece
The conduct of micro-blasting on PVD films for improving the cutting performance of coated tools is often encountered in industry. In the present paper, the effect of micro-blasting procedures on the film mechanical properties, cutting edge geometry and thus on the tool life is introduced. A novel method for determining coating strength properties gradation after micro-blasting was developed. Ball cratering tests were carried out at the tool flank and rake, near the cutting edge, to detect potential coating thickness change after micro-blasting. Moreover the effect of micro-blasting conditions on the cutting edge geometry was examined by white light scanning and EDX microanalyses. The cutting performance of coated tools subjected to films’ micro-blasting was investigated in milling. FEM supported calculations of the developed temperatures and stresses during material removal contributed for explaining the obtained tool wear results and herewith for optimizing the micro-blasting process.
10:30
Coffee break
10:50
Challenges in Processing and Characterization of Thermal Sprayed Coatings
Prof. Simo-Pekka Hannula* et al.
Aalto University School of Science and Technology, Finland
Thermal spraying is a very complex process including a number of variables. Particle melting stage and possible phase transformations during the flight must be controlled as well as coating build up mechanism including splat interface and stress stages. Better understanding of the relationship of these variables, and effect of those on the coating properties must be obtained. The process mapping tools have been developed to on carry out systematic process optimization and to achieve a better understanding of the process – microstructure – property relationships. Effective use of process mapping concept requires also reliable methods for characterizing coating microstructure and properties. In this paper the challenges in utilizing the process mapping concept and characterizing the coatings obtained are discussed.
11:30
Energy and Material Efficiency
Dr. Julian M. Allwood
University of Cambridge, United Kingdom
Avoiding the threat of severe climate change requires a reduction in global carbon emissions of 60-80% from present levels by 2050. One response to this threat is to focus on energy supply, in the hope that non-carbon emitting sources of energy can substitute existing supplies which are mainly derived from fossil fuels. Renewable energy sources have a low power density and sequestration of carbon is not fully tested at scale and carries high risks, so the major low carbon supply option is from nuclear electricity. However, it will be shown that a much cheaper and lower risk strategy would be to pursue energy efficiency to reduce demand for energy supplies. A global map of energy flow is presented, to allow evaluation of energy demand reductions, and analytical models are used to demonstrate that approximately 85% of current demand could be saved by efficiency measures, without loss of service. Most of these savings occur in the operation of buildings or transport, but in industry, where energy efficiency has already been a priority, the potential savings are much smaller. Instead, equivalent savings could be achieved by pursuit of material efficiency – using less primary material to provide material services. The options for delivering material efficiency, the barriers to achieving it, and the options for overcoming those barriers are briefly reviewed.
12:10
Lunch
13:40
Prediction of Property of Metal Forming Product by the Finite Element Method
Prof. Kozo Osakada*, Prof. Jun Yanagimoto
Osaka University, Japan
Methods for predicting the properties of the products manufactured by metal forming are explained, and examples of prediction are given. For cold forming, elimination of shape defects by extrusion against a pressure supported tool, accuracy prediction of cold formed products, effect of forging speed on mechanical properties, handlings of ductile fracture and surface property are discussed. As for hot forming, micro-structure evolution is explained in relation to temperature and strain histories during and after metal forming. Methods for predicting the mechanical properties after hot forming from the micro-structure are discussed.
14:20
Including the Effect of Manufacturing in the Design of Products: Crash Properties
Prof. Karl Roll
Daimler AG
The industrial forming simulation used today is the result of a development process during the last two decades. A main focus of this process was the continuous optimization to characterize the material properties. The presentation will give an overview of the simulation technology challenges arising from the need to improve bridging of the gaps between forming simulation and crash simulation. Furthermore, an integrated technology pathway from the per¬spective of simulation requirements, material characterization needs, simulation technology in¬novations, and impacts of those requirements on the accuracy of practical applications in the automotive world is discussed.
15:00
Planning of Manufacturing Processes for Graded Components
Prof. Jürgen Gausemeier* et al.
Universität Paderborn
Components with graded properties are a resource-conserving alternative to today’s composite materials. Functional gradation means a steady gradient of the property values through the three spatial dimensions of the component. For the computer-oriented description of the components as well as for the planning of the corresponding manufacturing processes a new method is required. This work presents a comprehensive framework for the computer aided planning of these manufacturing processes. Starting with the component description realised through a voxelmodel, manufacturing process chains are synthesised. The process parameters for the used manufacturing technologies are optimised in a following step. The optimised process chain is specified and gives the initial information for the implementation of the manufacturing system.
15:40
Coffee break
16:00
Design in an extended Virtual Product Creation Environment
Prof. Frank-Lothar Krause
Berliner Kreis
The paper analyses the dramatic changes in demands for products, reflects these new demands and how they are transformed by product developers to new products. The increasing complexity of global demands is mirrored with the increasing complexity of computer supported solution processes. Power and deficits in current methods, tools and systems are described and needed research effort is identified. To be able to cope with changing complex demands with a user friendly flexible system world the development of assistance systems is proposed.
16:40
Predicting Properties of Materials with X-Rays: The Application of Synchrotron Radiation in Materials Science
Prof. Metin Tolan* et al.
TU Dortmund
The use of synchrotron radiation for material analysis has become an important research area in materials science. In this work the synchrotron radiation source DELTA at the TU Dortmund is presented in the framework of material analysis. An x-ray adsorption spectroscopy experiment on the formation of iron oxide and an x-ray diffraction study of the temperature induced phase transition of cobalt is presented.

* Speaker

Note: The conference program is subject to change.

This conference is sponsored by the TU Dortmund.