In this project, two broad facets in the design of a methodology for performance optimization of indexable carbide inserts were examined. They were physical destructive testing and software simulation.For the physical testing, statistical research techniques were used for the design of the methodology. A five step method which began with Problem definition, through System identification, Statistical model formation, Data collection and Statistical analyses and results was indepthly elaborated upon. Set-up and execution of an experiment with a compression machine together with roadblocks and possible solution to curb road blocks to quality data collection were examined. 2k factorial design was illustrated and recommended for process improvement. Instances of first-order and second-order response surface analyses were encountered. In the case of curvature, test for curvature significance with center point analysis was recommended. Process optimization with method of steepest ascent and central composite design or process robustness studies of response surface analyses were also recommended.For the simulation test, AdvantEdge program was identified as the most used software for tool development. Challenges to the efficient application of this software were identified and possible solutions proposed. In conclusion, software simulation and physical testing were recommended to meet the objective of the project.

<p>Today, tool center point calibration is mostly done by a manual procedure. The method is very time consuming and the result may vary due to how skilled the operators are.</p><p>This thesis proposes a new automated iterative method for tool center point calibration of industrial robots, by making use of computer vision and image processing techniques. The new method has several advantages over the manual calibration method. Experimental verifications have shown that the proposed method is much faster, still delivering a comparable or even better accuracy. The setup of the proposed method is very easy, only one USB camera connected to a laptop computer is needed and no contact with the robot tool is necessary during the calibration procedure.</p><p>The method can be split into three different parts. Initially, the transformation between the robot wrist and the tool is determined by solving a closed loop of homogeneous transformations. Second an image segmentation procedure is described for finding point correspondences on a rotation symmetric robot tool. The image segmentation part is necessary for performing a measurement with six degrees of freedom of the camera to tool transformation. The last part of the proposed method is an iterative procedure which automates an ordinary four point tool center point calibration algorithm. The iterative procedure ensures that the accuracy of the tool center point calibration only depends on the accuracy of the camera when registering a movement between two positions.</p>

Localization and mapping are vital capabilities for a mobile robot. These two capabilities strongly depend on each other and simultaneously executing both of these operations is called SLAM (Simultaneous Localization and Mapping). SLAM problem requires the environment to be represented with an abstract mapping model. It is possible to construct a map from point cloud of environment via scanner sensor systems. On the other hand, extracting higher level of features from point clouds and using these extracted features as an input for mapping system is also a possible solution for SLAM. In this work, a 4D feature based EKF SLAM system is constructed and open form of equations of algorithm are presented. The algorithm is able to use center of mass and direction of features as input parameters and executes EKF SLAM via these parameters. Performance of 4D feature based EKF SLAM was examined and compared with 3D EKF SLAM via monte-carlo simulations. By this way / it is believed that, contribution of adding a direction vector to 3D features is investigated and illustrated via graphs of monte-carlo simulations. At the second part of the work, a scanner sensor system with IR distance finder is designed and constructed. An algorithm was presented to extract planar features from data collected by sensor system. A noise model was proposed for output features of sensor and 4D EKF SLAM algorithm was executed via extracted features of scanner system. By this way, performance of 4D EKF SLAM algorithm is tested with real sensor data and output results are compared with 3D features. So in this work, contribution of using 4D features instead of 3D ones was examined via comparing performance of 3D and 4D algorithms with simulation results and real sensor data.

Localization and mapping are vital capabilities for a mobile robot. These two capabilities strongly depend on each other and simultaneously executing both of these operations is called SLAM (Simultaneous Localization and Mapping). SLAM problem requires the environment to be represented with an abstract mapping model. It is possible to construct a map from point cloud of environment via scanner sensor systems. On the other hand, extracting higher level of features from point clouds and using these extracted features as an input for mapping system is also a possible solution for SLAM. In this work, a 4D feature based EKF SLAM system is constructed and open form of equations of algorithm are presented. The algorithm is able to use center of mass and direction of features as input parameters and executes EKF SLAM via these parameters. Performance of 4D feature based EKF SLAM was examined and compared with 3D EKF SLAM via monte-carlo simulations. By this way / it is believed that, contribution of adding a direction vector to 3D features is investigated and illustrated via graphs of monte-carlo simulations. At the second part of the work, a scanner sensor system with IR distance finder is designed and constructed. An algorithm was presented to extract planar features from data collected by sensor system. A noise model was proposed for output features of sensor and 4D EKF SLAM algorithm was executed via extracted features of scanner system. By this way, performance of 4D EKF SLAM algorithm is tested with real sensor data and output results are compared with 3D features. So in this work, contribution of using 4D features instead of 3D ones was examined via comparing performance of 3D and 4D algorithms with simulation results and real sensor data.

This study focuses on assessing the accuracy of the Euler-Bernoulli beam theory as computational bases to calculate strain and deflection of composite sandwich beam subjected to three-point and four-point bending. Two groups of composite sandwich beams tests results will be used for comparison purposes. Mechanical properties for the laminated skin are provided by researchers from University of Mississippi (Ellen Lackey et al., 2000). Mechanical properties for the balsa wood core are provided by Alcan Baltek Corporation. Appropriate material properties and test geometries are then used in the Euler-Bernoulli-based algorithm in order to generate analytical data for comparison to experimental data provided by researchers from University of New Orleans (UNO, 2005). The resulting single material cross section is then analyzed in the traditional manner using the Euler-Bernoulli beam theory. In general, the Euler-Bernoulli beam theory provides an appropriate analytical approach in predicting flexural behavior of composite sandwich beams.

Today, tool center point calibration is mostly done by a manual procedure. The method is very time consuming and the result may vary due to how skilled the operators are. This thesis proposes a new automated iterative method for tool center point calibration of industrial robots, by making use of computer vision and image processing techniques. The new method has several advantages over the manual calibration method. Experimental verifications have shown that the proposed method is much faster, still delivering a comparable or even better accuracy. The setup of the proposed method is very easy, only one USB camera connected to a laptop computer is needed and no contact with the robot tool is necessary during the calibration procedure. The method can be split into three different parts. Initially, the transformation between the robot wrist and the tool is determined by solving a closed loop of homogeneous transformations. Second an image segmentation procedure is described for finding point correspondences on a rotation symmetric robot tool. The image segmentation part is necessary for performing a measurement with six degrees of freedom of the camera to tool transformation. The last part of the proposed method is an iterative procedure which automates an ordinary four point tool center point calibration algorithm. The iterative procedure ensures that the accuracy of the tool center point calibration only depends on the accuracy of the camera when registering a movement between two positions.

Die Forschungsarbeiten der 19 Teilprojektes des SFB/TR 96 verfolgen den Ansatz, spanende Werkzeugmaschinen zu Fertigungsqualität und Wirtschaftlichkeit unter den Bedingungen einer energieeffizienten Produktion durch konstruktive und steuerungstechnische Lösungen zu befähigen. Damit besteht das Ziel des SFB/TR 96 in der Lösung des Zielkonflikts von Energieeinsatz, Genauigkeit und Produktivität bei der spanenden Fertigung.

Die Forschungsarbeiten der 19 Teilprojektes des SFB/TR 96 verfolgen den Ansatz, spanende Werkzeugmaschinen zu Fertigungsqualität und Wirtschaftlichkeit unter den Bedingungen einer energieeffizienten Produktion durch konstruktive und steuerungstechnische Lösungen zu befähigen. Damit besteht das Ziel des SFB/TR 96 in der Lösung des Zielkonflikts von Energieeinsatz, Genauigkeit und Produktivität bei der spanenden Fertigung.:Motivation und Überblick Christian Brecher (RWTH Aachen, Sprecher des SFB/TR 96) Erstellung und Abgleich eines strukturbasierten thermischen Modells der kugelgewindegetriebenen Vorschubachse eines Hexapoden Alexander Galant, Steffen Schroeder, Bernd Kauschinger (IWM TU Dresden) Michael Beitelschmidt (IFKM TU Dresden) Wärme im Zerspanungsprozess und ihre Wirkung im Werkzeug Matthias Putz, Gerhard Schmidt, Ulrich Semmler (IWU Chemnitz) Michael Bräunig (IWP TU Chemnitz) Fritz Klocke, Drazen Veselovac, Matthias Brockmann, Thorsten Augspurger, Patrick Mattfeld, Matthias Rasim, Christian Wrobel (Lehrstuhl für Technologie der Fertigungsverfahren RWTH Aachen) Parameteridentifikation in thermo-elastischen Systemen Roland Herzog, Ilka Riedel (Professur für Numerische Mathematik (partielle Differentialgleichungen) TU Chemnitz) Bernd Kauschinger, Steffen Schroeder (IWM TU Dresden) Prognose von Verlustleistungen und Kontaktwärmeübergängen an Maschinenkomponenten Christian Brecher, Marcel Fey, Kolja Bakarinow, Stephan Neus (Lehrstuhl für Werkzeugmaschinen RWTH Aachen) Reinhold Kneer, Yona Frekers (WSA RWTH Aachen) Berechnung von thermo-elastischen Deformationen in Werkzeugmaschinen – Vergleich numerischer Verfahren – Michael Beitelschmidt, Marian Partzsch (IFKM TU Dresden) Peter Benner, Norman Lang (MiIT TU Chemnitz) Andreas Naumann, Axel Voigt, Jörg Wensch (IWR TU Dresden) Analyse der Wärmeentstehung im Antrieb und Temperierung von Strukturen und Antrieben am Beispiel von Werkzeugmaschinen Stefan Winkler, Ralf Werner (EWA TU Chemnitz) Andre Bucht, Welf-Guntram Drossel (Fraunhofer IWU) Jürgen Weber, Juliane Weber (IFD TU Dresden) Immanuel Voigt (IWP TU Chemnitz) Experimenteller Vergleich kennfeld- und strukturmodellbasierter Korrektur Steffen Ihlenfeldt, Christian Naumann (Fraunhofer IWU) Xaver Thiem, Mirko Riedel, Bernd Kauschinger (IWM TU Dresden) Zeitabhängige Beschreibung volumetrischer thermo-elastischer Verlagerungen von Werkzeugmaschinen Christian Brecher, Marcel Fey, Matthias Wennemer (Lehrstuhl für Werkzeugmaschinen RWTH Aachen) Messtechnisch basierte Ansätze zur Korrektur thermischer Verlagerungen Mirko Riedel, Jens Müller (IWM TU Dresden) Michel Klatte, Christian Wenzel (Fraunhofer IPT) Bewertung thermisch bedingter Verlagerungen mit Prüfwerkstücken Hajo Wiemer, Hubert Höfer (IWM TU Dresden)

Die Dresdner Werkzeugmaschinen-Fachseminare sind ein Forum zu ausgewählten Spezialthemen der Entwicklung und Nutzung von Werkzeugmaschinen. Das 16. WZM-Fachseminar berichtetet inhaltlich detailliert von aktuellen Arbeiten im Rahmen des DFG-Sonderforschungsbereiches "Thermo-Energetische Gestaltung von Werkzeugmaschinen" (SFB/TR 96) an den Standorten Dresden, Aachen und Chemnitz. Die Fachbeiträge berichten über experimentelle und modellgestützte Analyse von Wärmequellen und -übertragung in spanenden Werkzeugmaschinen sowie zu Lösungsansätzen zur Korrektur und Kompensation der thermo-elastischen Verlagerungen.

Die Dresdner Werkzeugmaschinen-Fachseminare sind ein Forum zu ausgewählten Spezialthemen der Entwicklung und Nutzung von Werkzeugmaschinen. Das 16. WZM-Fachseminar berichtetet inhaltlich detailliert von aktuellen Arbeiten im Rahmen des DFG-Sonderforschungsbereiches "Thermo-Energetische Gestaltung von Werkzeugmaschinen" (SFB/TR 96) an den Standorten Dresden, Aachen und Chemnitz. Die Fachbeiträge berichten über experimentelle und modellgestützte Analyse von Wärmequellen und -übertragung in spanenden Werkzeugmaschinen sowie zu Lösungsansätzen zur Korrektur und Kompensation der thermo-elastischen Verlagerungen.:H. P. Schossig DMG, Pfronten: Thermik-Forschung und die Umsetzung der Erkenntnisse in Maschinenkonzepten bei DMG K. Großmann Sprecher des DFG-SFB Transregio 96 IWM, TU Dresden: Thermo-Energetische Gestaltung von Werkzeugmaschinen F. Klocke; M. Brockmann WZL, RWTH Aachen, K. Großmann; Ch. Städel IWM, TU Dresden: Untersuchungen des Zerspanungsprozesses hinsichtlich auftretender Wärmeströme und Temperaturen R. Werner; St. Winkler EWA, TU Chemnitz, Ch. Brecher; D. Haber WZL, RWTH Aachen: Verlustleistungen in einer Vorschubachse und die daraus resultierende Temperaturverteilung R. Kneer; S. Vieler WSA, RWTH Aachen, K. Großmann; St. Schroeder IWM, TU Dresden: Messungen des Wärmeübergangs an Fugenkontakten von Werkzeugmaschinen J. Weber; Jul. Weber IFD, TU Dresden, G. Schmidt; U. Semmler Fraunhofer IWU, Chemnitz: Fluidische Kühlung von Motorspindeln und Werkzeugen W.-G. Drossel; St. Ihlenfeldt; C. Zwingenberger Fraunhofer IWU, Chemnitz, K. Großmann; St. Schroeder IWM, TU Dresden: Modellierung des Wärmeaustauschs Maschine-Umgebung A. Voigt; J. Wensch; A. Naumann IWR, TU Dresden: Defektkorrektur bei Mittelungsverfahren in der Zeitintegration des Temperaturverhaltens K. Großmann; A. Galant IWM, TU Dresden, M. Beitelschmidt; M. Partzsch IFKM, TU Dresden: Strukturveränderlichkeit in FEM und Blocksimulation bei der Berechnung von Temperaturfeldern K. Großmann; M. Merx IWM, TU Dresden: Thermografie und Nahbereichs-Fotogrammetrie zur Erfassung von Temperatur- u. Verlagerungsfeldern Ch. Brecher; M. Wennemer WZL, RWTH Aachen: Eigenschaftsmodellbasierter Ansatz zur Korrektur thermo-elastischer Verlagerungen K. Großmann; Ch. Städel IWM, TU Dresden: Simulative Erweiterung der Datenbasis zur korrelativen Korrektur thermo-elastischer Verlagerungen W.-G. Drossel; Ch. Ohsenbrügge Fraunhofer IWU, Chemnitz: Materialeffekte und Funktionsmechanismen zur Wärmefluss-Steuerung