Efficiency of the Manufacturing Processes

11B2311

Bachelor

German

5.0

only winter term

1 semester

The efficiency of manufacturing processes is crucial to the economic success of a company. Efficient manufacturing processes help to increase productivity, reduce costs and improve the quality of the manufactured products. At the same time, this goes hand in hand with sustainability considerations, so that products can be manufactured with minimized use of raw materials and energy through the correct selection and further development of manufacturing processes. Machining, additive and forming manufacturing processes are controlled manufacturing processes and therefore have a high potential for efficiency in process execution. Knowledge of the possibilities and limitations of the various manufacturing processes and physical relationships is the basis for process selection and effective process design.

Most of the added value in production is achieved with subtractive machining processes that work with simple tool geometries. Due to their precision potential, they are indispensable for machining complex products with increasingly smaller tolerances in dimensions and shapes and because of their high productivity across the entire spectrum from one-off production to large series.

By joining elementary volume elements - in thin layers or continuously - additive processes enable the tool-free production of geometries that are not subject to any restrictions due to accessibility for machining tools. The working accuracy of additive processes is inferior to fine machining, so that hybrid processes are being developed with a machining reworking of the additive parts.

In forming manufacturing processes, the shapes of workpieces are changed by applying pressure or tensile forces without removing any material. These processes therefore play an important role with regard to material-efficient product manufacture.

Excursions are carried out as required to accompany the course.

1. introduction and correlations -> differentiation of cutting, additive and forming manufacturing processes, development of the processes with a view to energy and sustainability aspects

2. machining with geometrically defined cutting edges -> movements, engagement and chip sizes, cutting edge geometries, chip formation, chip types and chip shapes, forces, energy and power during machining, machining processes, cutting materials, cooling lubricant systems

3. cutting with geometrically indeterminate cutting edges -> processes, calculation of effective criteria, energy and power considerations

4. high-performance machining -> HPC and HSC milling, machining of hardened steels and hard metals, minimum quantity lubrication and dry machining

5. additive manufacturing processes -> process basics and process variants, component development and support structures, design of additive manufacturing systems, laser-based systems, efficiency potentials

6. increasing efficiency in manufacturing processes -> lean principles, automation, integration of digital technologies, determination and improvement of the CO2 footprint

7. planning and calculating production sequences -> possible combinations of production processes, energy efficiency of a process combination

The total workload for the module is 165 hours (see also "ECTS credit points and grading").

• Written examination

• Field work / Experimental work

Advanced mathematics, statics, strength of materials, basic knowledge of measurement technology, Windows applications

Students recognize the interrelationships in the system of modern and additive processes, assess the work result and analyze the interaction between input variables, effect criteria and technological parameters.

Students have a complete and integrated knowledge of most core areas and fundamental aspects of manufacturing processes.

• Sachnik, Peter

• Sachnik, Peter