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Prof. Dr.-Ing. Nikolaus Urban

Faculty of Applied Natural Sciences and Industrial Engineering

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Professor

L 210

0991/3615-8279

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NewspaperArticle
  • J. Hofmann
  • Nikolaus Urban

Industrie 4.0 im Elektromaschinenbau.

In: Industrieanzeiger vol. 2016 pg. 28-29

  • (2016)
Contribution
  • A. Meyer
  • A. Heyder
  • M. Brela
  • Nikolaus Urban
  • J. Sparrer
  • J. Franke

Fully automated rotor inspection apparatus with high flexibility for permanent magnet synchronous motors using an improved hall sensor line array.

In: 2015 5th International Electric Drives Production Conference (EDPC). pg. 1-5

IEEE

  • (2015)

DOI: 10.1109/EDPC.2015.7323196

show abstract

As a result of the market expansion of permanent magnet synchronous motors due to the increasing demand for high-performance drives for a wide range of applications such as traction drives for electric mobility, positioning drives for machine tools as well as high-precision drives for special-purpose machines and the quality demands involved, in-line capable measurement technology is needed. Thus in the area of electric drives manufacturing the rejection rate is required to be reduced by early fault detection. This can be achieved by measuring the rotor excitation field created by permanent magnets prior to the assembly of rotor and stator. In this Paper an apparatus for fully automated inspection of both internal and external rotors within a wide range of dimensions is presented. This is done with the aid of a one dimensional Hall-Sensor line array, which is manufactured with high accuracy and the use of an open source CNC system. The presented device is capable for in-line operation at the end of the rotor assembly process chain to detect possible magnetization and assembly faults prior to the final assembly of the electric drive by visualization of the rotor excitation field.
Contribution
  • T. Kolb
  • F. Huber
  • B. Akbulut
  • C. Donocik
  • Nikolaus Urban
  • D. Maurer
  • J. Franke

Laser Beam Melting of NdFeB for the production of rare-earth magnets.

In: 2016 6th International Electric Drives Production Conference (EDPC). pg. 34-40

IEEE

  • (2016)

DOI: 10.1109/EDPC.2016.7851311

show abstract

Concerning rare-earth materials additive techniques like hollow cathode discharging or magnetron sputtering have been used to produce thin films, e.g. for the application in microelectromechanical systems (MEMS). In this paper our investigations in additively processing NdFeB-powder materials by means of laser beam melting in a powder bed (LBM) in order to produce macroscopic, three-dimensional specimens are presented. In this context we explain the advantages of additively manufactured magnets in comparison to conventional production methods. Furthermore different rare-earth-material powders were characterized with respect to their suitability for the LBM process. We describe a melting or sintering of the material at varying process parameters to obtain test cubes. Those specimens were magnetized and their magnetic field was analyzed. Additionally the density and microstructure of the samples was investigated. Subsequently we conclude this paper by presenting future steps of our research.
Journal article
  • Nikolaus Urban
  • Alexander Meyer
  • Sven Kreitlein
  • Felix Leicht
  • Jörg Franke

Efficient near Net-Shape Production of High Energy Rare Earth Magnets by Laser Beam Melting.

In: Applied Mechanics and Materials vol. 871 pg. 137-144

  • (2017)

DOI: 10.4028/www.scientific.net/AMM.871.137

show abstract

In this publication we report on our progress in investigating the energy efficient production of rare earth permanent magnets by Laser Beam Melting in the powder bed (LBM). This innovative additive manufacturing process offers the potential to produce magnets of complex geometries without an energy intensive oven sintering step. Another advantage that increases the efficiency of this possible new process route is the high degree of material utilization due to a near net shape production of the magnets. Hence only little material is wasted during a post processing machining step. The main challenge in processing rare earth magnet alloys by means of LBM is the brittle mechanical behavior of the material and the change in microstructure due to the complete remelting of the magnet powder. We therefor expanded the parameter study presented in previous work in order to further increase relative density and magnetic properties of the specimens. In this context process stability and reproducibility could also be increased. This was achieved by investigating the impact of different exposure patterns and varying laser spot sizes. Simultaneously to the experiments the energy consumption of the LBM process was measured and compared with conventional rare earth magnet production routes.
Journal article
  • Michael Schneider
  • Nikolaus Urban
  • Alexander Meyer
  • Jörg Franke

Neuartiger Ansatz zur flexiblen Fertigung verlustoptimierter Statorblechpakete.

In: Zeitschrift für wirtschaftlichen Fabrikbetrieb vol. 112 pg. 225-228

  • (2017)

DOI: 10.3139/104.111702

show abstract

Die elektromagnetische Messung der spezifischen Verluste von lasergeschnittenen Ringkernproben, welche mit unterschiedlichsten Parametern hergestellt wurden, haben signifikante Unterschiede hervorgebracht. Die Ergebnisse der Messungen zeigen, dass es keineswegs eine allgemeingültige Aussage zur korrekten Parameterwahl bei der Fertigung zur Erzeugung optimaler Qualität gibt. Vielmehr kann aus den Ergebnissen abgeleitet werden, dass der Betriebsfall darüber entscheidet, welcher Parametersatz für die Einzellamellen gewählt werden sollten, um möglichst geringe Eisenverlusten zu erzielen. Zur Validierung der Qualität sind manuelle Stichprobenprüfungen ungeeignet, weshalb der Bedarf für Prüfverfahren besteht, welche eine 100 %-Prüfung innerhalb der Linie ermöglichen und somit eine vollautomatische aber dennoch flexible Fertigung zu entwerfen. Eine mögliche Prüfmethode wird in diesem Beitrag aufgezeigt.
Journal article
  • J. Zeitler
  • Nikolaus Urban
  • C. Kühn
  • J. Franke

Engineering von mechatronischen Baugruppen für die additive Fertigung.

In: Konstruktion vol. 69 pg. 67-82

  • (2017)

DOI: 10.37544/0720-5953-2017-11-12-67

show abstract

Als Reaktion auf den wachsenden Einfluss der Mechatronik auf die Industrie ist die additive Fertigung inzwischen so weit entwickelt, dass sie dazu in der Lage ist, die Bedürfnisse von räumlichen, hochintegrierten und interdisziplinären Baugruppen zu erfüllen. In Form eines hybriden, rein additiven Fertigungsprozesses können sowohl mechanische Substratkörper, elektrisch leitfähige Strukturen, sowie Inlets, die während des Fertigungsprozesses integriert werden, in einem einzigen Prozess zu einer Baugruppe kombiniert werden. Um diesen neuartigen Engineeringprozess zu unterstützen, werden innovative Ansätze und Werkzeuge der Konstruktionsmethodik vorgestellt.
Contribution
  • M. Schneider
  • Nikolaus Urban
  • J. Franke

Relation of joining parameters of stator core production and iron loss.

In: 2017 7th International Electric Drives Production Conference (EDPC). pg. 1-6

IEEE

  • (2017)

DOI: 10.1109/EDPC.2017.8328148

show abstract

The demand for environmentally friendly and sustainable mobility leads to the increasing spread of electric vehicles. An important part of the electric drive is the stator. This is made up of many laminated steel sheets. The production quality of such a laminated stator core is effected by the essential process steps of cutting, joining and winding. The causes of potential losses can arise in each of these phases. At high frequencies, the eddy current losses dominate the iron losses and thus also the major part of the total losses. Different manufacturing technologies for joining the laminations are often compared in literature to highlight differences. Within the scope of this publication, different joining technologies are compared with respect to the hysteresis and eddy current losses influenced by them. For this purpose, differently manufactured ring core samples with multiple production parameters are examined. In particular the increase of the iron losses caused by the local and global generation of conductive paths in the sheet metal package is the focus of interest here. Subsequently, the losses resulting from baked resin and welding joining technology are determined and compared by means of measurements. We present industry relevant results by considering the specific hysteresis and eddy current losses according to DIN DIN EN 60404-6. The experiments are carried out varying different process parameters like welding seams, welding energy, feed speed and pressure, baking time and temperature with regard to diameters of ring core samples.
Contribution
  • Nikolaus Urban
  • Florian Huber
  • Jorg Franke

Influences of process parameters on rare earth magnets produced by laser beam melting.

In: 2017 7th International Electric Drives Production Conference (EDPC). pg. 1-5

IEEE

  • (2017)

DOI: 10.1109/EDPC.2017.8328149

show abstract

Powerful permanent magnets are of essential meaning for electric drives as well as for environmental friendly energy production. To meet industrial requirements like high energy products, thermal stability and acceptable price mostly NdFeB-based alloys are taken into account. For these alloys, a trade-off has to be made when it comes to net-shape production. Either simple geometries can be produced maxing out the full magnetic potential of the material, or a nonmagnetic binder has to be used to produce more complex shapes at the price of reduced magnetic properties. To overcome these limitations, we present a detailed study on additive manufacturing of an NdFeB-alloy by Laser Beam Melting. By employing this technology, nearly any shape can be produced in a single process without using a secondary material or extensive post processing.
Journal article
  • A. Meyer
  • S. Abersfelder
  • Nikolaus Urban
  • M. Schneider
  • J. Franke

Fertigungsbegleitende Qualitätskontrolle in der Elektromotorenfertigung.

In: Zeitschrift für wirtschaftlichen Fabrikbetrieb vol. 112 pg. 200-203

  • (2017)

DOI: 10.3139/104.111694

show abstract

Permanent erregte Synchronmotoren zeichnen sich durch hochdynamisches Betriebsverhalten bei sehr guter Regelbarkeit und Leistungsdichte aus. Die Laufeigenschaften dieser Antriebe unterliegen fertigungsbedingter Abweichungen. Insbesondere die weitgehend fehlende Qualitätskontrolle des Rotormagnetfeldes vor dem Fügen von Rotor- und Statorbaugruppe lässt eine Beurteilung der Leistung sowie der Drehmomentschwankungen erst in der Endkontrolle zu. Dieser Beitrag beschreibt somit die Möglichkeiten und Potenziale einer In-Line-Qualitätskontrolle in der Rotorfertigung.
Journal article
  • S. Kreitlein
  • V. Gerter
  • Nikolaus Urban
  • J. Franke

Crossbench and Evaluation of Additive Manufacturing Processes in Strategy of Sustainable and Energy Efficient Production.

In: Applied Mechanics and Materials vol. 871 pg. 145-152

  • (2017)

DOI: 10.4028/www.scientific.net/AMM.871.145

show abstract

This paper presents the Least Energy Demand as an independent reference value for evaluating energy efficiency of additive manufacturing (AM) processes. Nowadays an essential challenge is represented by a proper evaluation and calculation of the energy efficiency of production processes. The reason for this is the lack of appropriate reference values. A comprehensive comparison of the energy efficiency is not possible without consistent reference values. However, this comparison serves as a first step towards the goal in order to reveal the actual energy savings potential of additive manufacturing procedures and to take actions on this basis. Therefore, as a first step the basic concept of the additive manufacturing principle is introduced. Subsequent the scope of the current research regarding the considered additive manufacturing techniques is illustrated. Afterwards the general system of the Least Energy Demand is presented, which serves the needs in terms of evaluating the energy efficiency of additive manufacturing processes. To sustain the comparability of the Least Energy Demand between the presented AM-procedures a solid basis for further calculations is established. Finally this paper concludes with the results of the calculated Least Energy Demands for the individual additive manufacturing processes and a comprehensive energetic comparison.
Journal article
  • S. Kreitlein
  • V. Gerter
  • Nikolaus Urban
  • J. Franke

Evaluation and Assessment of Additive Manufacturing Processes Based on the Least Energy Demand in Application for Sustainable Production.

In: Applied Mechanics and Materials vol. 871 pg. 153-160

  • (2017)

DOI: 10.4028/www.scientific.net/AMM.871.153

show abstract

This paper presents the Least Energy Demand as an independent reference value for evaluating energy efficiency of additive manufacturing (AM) processes. Nowadays an essential challenge is represented by a proper evaluation and calculation of the energy efficiency of production processes. The reason for this is the lack of appropriate reference values. A comprehensive comparison of the energy efficiency is not possible without consistent reference values. However, this comparison serves as a first step towards the goal in order to reveal the actual energy savings potential of additive manufacturing procedures and to take actions on this basis. Therefore, the first step is to define the general concept, which is used for the calculation of the Least Energy Demand. Moreover, the unit operation-specific Least Energy Demand E GM is introduced based on unit operations. In conclusion, the importance of E GM as a reference value for evaluating the energy efficiency of production processes, defined in DIN 8580, is explained. Within the scope of an application of the illustrated concept the Least Energy Demand and the Relative Energy Efficiency (REE) are calculated using the example of a selective laser melting process.
Contribution
  • Nikolaus Urban
  • Alexander Meyer
  • Moritz Leckel
  • Michael Leder
  • Jorg Franke

Additive Manufacturing of an Electric Drive a Feasability Study.

In: 2018 International Symposium on Power Electronics, Electrical Drives, Automation and Motion (SPEEDAM). pg. 1327-1331

IEEE

  • (2018)

DOI: 10.1109/SPEEDAM.2018.8445258

show abstract

Additive manufacturing (AM) of end-use products is becoming more important to a variety of different industry sectors. Increasingly, more companies are utilizing the specific characteristics such as lightweight construction potential, functional integration and cost advantages in the area of small quantities for their production. Up to now, the additive manufactured components fulfil their function mainly by their geometric form. In order to elevate AM to the next level of functionality, it is necessary to directly generate mechatronised products and integrate electrical, thermal, magnetic or cognitive capabilities directly during production. In this publication we demonstrate that this is already partly possible by means of a nearly completely additive manufactured small electric motor.
Contribution
  • K. Lomakin
  • T. Pavlenko
  • M. Sippel
  • G. Gold
  • K. Helmreich
  • M. Ankenbrand
  • Nikolaus Urban
  • J. Franke

Impact of Surface Roughness on 3D Printed SLS Horn Antennas.

In: 12th European Conference on Antennas and Propagation (EuCAP 2018). pg. 1-4

Institution of Engineering and Technology

  • (2018)

DOI: 10.1049/cp.2018.1235

show abstract

This work compares a pyramid horn antenna printed by selective laser sintering (SLS) process from stainless steel powder with a commercially available cast metal horn. Although exhibiting significant surface roughness and lower conductivity, the printed specimen shows almost identical performance as compared to the cast metal reference. The measurement results are analyzed and the impact of surface roughness is attributed to physical relations which can be represented by using an effective, frequency dependent conductivity.
Contribution
  • A. Mayr
  • M. Weigelt
  • J. Lindenfels
  • J. Seefried
  • M. Ziegler
  • A. Mahr
  • Nikolaus Urban
  • A. Kuhl
  • F. Huttel

Electric Motor Production 4.0 – Application Potentials of Industry 4.0 Technologies in the Manufacturing of Electric Motors.

In: 2018 8th International Electric Drives Production Conference (EDPC). pg. 1-13

IEEE

  • (2018)

DOI: 10.1109/EDPC.2018.8658294

show abstract

Industry 4.0 (I4.0) is accompanied by a variety of technologies which offer great potential for optimizing the manufacturing of electric motors. However, the application of I4.0 technologies in this sector has hardly been examined yet. For determining I4.0 potentials in the electric motor production, a structured approach is required since the variety of sub-processes and production technologies results in a vast number of possible combinations. Therefore, this paper first compares different generic approaches for identifying, selecting and implementing I4.0 use cases. Building on this, a methodical approach is derived in order to tap the numerous I4.0 potentials within the electric motor production. On the one hand, use cases can be derived from current technological opportunities resulting from application examples and best practices in research and industry. On the other hand, concrete problems in critical manufacturing processes can give rise to the application of novel I4.0 solutions. By presenting a comprehensive overview of promising application scenarios, this paper mainly facilitates the identification of I4.0 potentials in the electric motor production from an opportunity-driven perspective. In addition to approaches directly addressing the electric motor production, concepts can be derived from related processes in other application domains. Examples are provided by outlining a selection of the presumably most relevant use cases. The results indicate that especially data-driven approaches, i.e. data analytics and machine learning, offer great potential in electric motor production. As an outlook, I4.0 potentials can also be disclosed from a problem-pull perspective, supplementing the opportunity-push approach of this paper.
Journal article
  • Nikolaus Urban
  • A. Meyer
  • V. Keller
  • J. Franke

Contribution of Additive Manufacturing of Rare Earth Material to the Increase in Performance and Resource Efficiency of Permanent Magnets.

In: Applied Mechanics and Materials vol. 882 pg. 135-141

  • (2018)

DOI: 10.4028/www.scientific.net/AMM.882.135

show abstract

Powerful permanent magnets are of essential meaning for electric drives as well as for environmental friendly energy conversion in general. The main requirements for these applications are high energy products, coercivity and remanent polarization, thermal stability as well as affordable price. As state of the art, rare earth permanent magnets, frequently consisting of NdFeB based alloys, meet these requirements. When complex geometric shapes like arcs, shells or freeform surfaces are required by the application, a trade-off has to be taken into account between magnetic performance and post magnet-fabrication processing steps. Either bonded magnets can be produced with great variety of geometries while accepting low magnetic performance due to a significant amount of nonmagnetic plastic binder matrix, or sintered blocks with great magnetic performance have to be machined out to the specified shape accepting great effort for grinding or wire cutting as well as a significant loss of valuable material. To overcome the drawback of both conventional established magnet manufacturing processes, Laser Beam Melting (LBM) is investigated to provide an alternative process route for magnet production. This innovative Additive Manufacturing (AM) process offers tool less production of nearly any thinkable geometry by use of a metal powder bed fusing process. Due to the challenging material behavior, a detailed parameter study is presented including a systematic design of experiment (DoE) approach. The connection between process parameters, density and key performance indicators on the B/H-curve is broken down.
Lecture
  • Nikolaus Urban
  • M. Kühl
  • M. Glauche
  • J. Franke

Additive Manufacturing of Neodymium-Iron-Boron Permanent Magnets.

In: 2018 8th International Electric Drives Production Conference (EDPC)

IEEE Schweinfurt

  • 04.-05.12.2018 (2018)
Contribution
  • J. Lindenfels
  • Nikolaus Urban
  • A. Mayr
  • A. Meyer
  • J. Franke

Advances in Quality Monitoring of Stray Fields on Rotors of Permanent Magnet Synchronous Motors.

In: 2019 9th International Electric Drives Production Conference (EDPC). pg. 1-6

IEEE

  • (2019)

DOI: 10.1109/EDPC48408.2019.9012022

show abstract

For industrial applications and as traction drives for electric cars, permanent magnet synchronous motors are widely used. They are characterised by excellent dynamic operating behaviour with very good controllability and power density. However, their quality characteristics are influenced by deviations due to material and production variances. One approach for quality control can be the monitoring of the stray field of the rotor magnetic field before joining the rotor into the stator. In doing so, rotor deviations can be detected and effects on the overall motor be predicted, e.g. fluctuations of the power or increased cogging torques. In this paper, the application purposes and restrictions of this monitoring approach are shown. A special focus is set on presenting the current development status of the rotor test bench, which has already been presented in earlier work. In this context, a calibration method for hall sensor arrays is introduced to further improve the quality assurance in rotor production. By integrating a laser distance sensor into the measuring setup, a better localization of deviations can be achieved.
Lecture
  • Nikolaus Urban
  • L. Bauch
  • R. Armbruster
  • J. Franke

Evaluation of soft magnetic ferrosilicon FeSi6.5 for laser beam melting.

In: 2019 9th International Electric Drives Production Conference (EDPC)

IEEE Esslingen

  • 03.-04.12.2019 (2019)
Contribution
  • Nikolaus Urban
  • J. Detrois
  • J. Franke

Correlation between Residual Stress, Building Angle and Illumination Parameters of Additive Manufactured FeSi6.5 and Mechanical and Magnetic Properties.

In: 2020 10th International Electric Drives Production Conference (EDPC). pg. 1-7

IEEE

  • (2020)

DOI: 10.1109/EDPC51184.2020.9388179

show abstract

Soft magnetic iron-silicon (FeSi) alloys are widely used in electromechanical energy converters. The addition of silicon to pure iron causes a reduction in electrical conductivity, which reduces the losses in energy conversion due to eddy currents. The main tasks of FeSi alloys are the low-loss guidance of the magnetic flux as well as the transfer of heat, torque and forces. Conventional processing is carried out by processing sheet material. The desired contour is cut out by punching, laser cutting or EDM, which is then stacked and joined to form a soft magnetic core. For high-alloy materials, punching in particular reaches its limits due to the brittle material behavior. Furthermore, punching processes are limited to axial symmetrical geometries. As a result, it is not economical to produce geometries adapted to an optimum magnetic flux path in the axial direction or to save material and thus weight in regions of low flux density. With Additive Manufacturing (AM), a workpiece is built up without tools, which enables a new dimension of the geometric design freedom. One method for AM of metals is laser beam melting (LBM). During the process, not only the geometry is materialized, but also the microstructure and hence the magnetic properties. Due to the working principle of LBM, residual stresses, which lead to deformation and to a reduction of the characteristic mechanical values, are inevitable. These downsides can be compensated by employing special pre-, in-and post-processing measures. The scope of this publication is to quantify the correlation between the part orientation inside the building chamber, residual stresses induced by different illumination patterns, and a post heat treatment process. The measurements are carried out under standardized conditions for better comparability with conventional materials.
Journal article
  • M. Skalon
  • M. Görtler
  • B. Meier
  • S. Arneitz
  • Nikolaus Urban
  • S. Mitsche
  • C. Huber
  • J. Franke
  • C. Sommitsch

Influence of Melt-Pool Stability in 3D Printing of NdFeB Magnets on Density and Magnetic Properties.

In: Materials (Basel, Switzerland) vol. 13 pg. 139

  • (2020)

DOI: 10.3390/ma13010139

show abstract

The current work presents the results of an investigation focused on the influence of process parameters on the melt-track stability and its consequence to the sample density printed out of NdFeB powder. Commercially available powder of Nd7.5Pr0.7Fe75.4Co2.5B8.8Zr2.6Ti2.5 alloy was investigated at the angle of application in selective laser melting of permanent magnets. Using single track printing the stability of the melt pool was investigated under changing process parameters. The influence of changing laser power, scanning speed, and powder layer thickness on density, porosity structure, microstructure, phase composition, and magnetic properties were investigated. The results showed that energy density coupled with powder layer thickness plays a crucial role in melt-track stability. It was possible to manufacture magnets of both high relative density and high magnetic properties. Magnetization tests showed a significant correlation between the shape of the demagnetization curve and the layer height. While small layer heights are beneficial for sufficient magnetic properties, the remaining main parameters tend to affect the magnetic properties less. A quasi-linear correlation between the layer height and the magnetic properties remanence (Jr), coercivity (HcJ) and maximum energy product ((BH)max) was found.
Contribution
  • Nikolaus Urban
  • M. Masuch
  • J. Paduch
  • J. Franke

An Approach to Eddy Current Reduction in Laser Powder Bed Fused High Silicon Steel Considering Manufacturing Influences.

In: 2021 11th International Electric Drives Production Conference (EDPC). pg. 1-5

IEEE

  • (2021)

DOI: 10.1109/EDPC53547.2021.9684214

show abstract

Additive manufacturing (AM) is a primary forming technology that makes it possible to produce previously impossible geometries and tailored properties by selectively adding material to a workpiece under computer control. For small to medium quantities, the processes grouped under this technology are already established in the industry. Metals are often processed by laser powder bed fusion (PBF- LB/M). With PBF- LB/M, different powder materials can be processed with identical system equipment. With the successive spread of this production technology, the processing of functional materials in the electro-mechanical-engineering industry is increasingly becoming the focus of interest for users. The processing of copper by PBF - LB/M is already state of the art. Soft magnetic materials are currently the subject of research work, and promising results have already been published. The realization of components that provide lowest possible energy losses is also of decisive importance in the context of electromagnetic energy converters. According to the state of the art, multi-material systems of metal and polymer or ceramic, as used for the conventional design of sheet metal packages or soft magnetic composites (SMC) cores, cannot be processed on PBF-LB/M systems. As an alternative, area-filling structures, which cannot be produced conventionally, are known to reduce losses. By including thin non-consolidated areas inside the workpiece, eddy current paths can be interrupted and losses reduced. Initial studies on this show promising potential. In this publication, different area-filling patterns are numerically evaluated based on the eddy current density in the sample crosssection. However, PBF -LB/M-specific manufacturing influences, such as welding through thin powder layers, prevent the direct transfer of the numerical investigations into practice. Therefore, a comparison is made in experimental studies, which qualitatively confirm the findings and provide promising approaches for loss reduction.
Contribution
  • M. Kratzer
  • J. Mayer
  • F. Höfler
  • Nikolaus Urban

Decision Support System for a Metal Additive Manufacturing Process Chain Design for the Automotive Industry.

In: Industrializing Additive Manufacturing. pg. 469-482

  • Eds.:
  • M. Meboldt
  • C. Klahn

Springer International Publishing Cham

  • (2021)

DOI: 10.1007/978-3-030-54334-1_33

show abstract

Additive Manufacturing (AM) is becoming increasingly important in various industries, particularly due to its freedom of design, functional integration and faster product development cycles. In many applications, additively manufactured components cannot be used directly after the printing process, but require subsequent process steps such as heat and surface treatment. A large number of process alternatives are available both for the execution of the printing process and for the subsequent steps. Hence, there are numerous possible combinations for the design of the entire production process chain. In order to simplify process selection in the area of AM, approaches and systems for decision support have already been developed in research. However, they do not consider the entire process chain including post-processing. This extended perspective is necessary to make full use of the technical potential of AM components and to optimize production with regard to economic criteria. Furthermore, automotive specifics regarding selection criteria and an underlying database of materials and processes are not taken into account in most cases. Thus, the following article presents a decision support system for the design of the entire production process chain in the conceptual planning phase. It will be useful for storage and retrieval of knowledge about process alternatives. The work focuses on the use of powder-bed-based metal AM in automotive applications. For this purpose, the process chains of Binder Jetting and Laser Powder Bed Fusion including their alternatives in post-processing are considered. Evaluation criteria and general conditions for automotive production are identified. Subsequently, the individual process steps and their properties are logically linked based on the defined criteria to support the selection of the optimal process chain. Finally, the methodology is demonstrated with an automotive component.
Thesis
  • Nikolaus Urban

Untersuchung des Laserstrahlschmelzens von Neodym-Eisen-Bor zur additiven Herstellung von Permanentmagneten.

In: FAU Studien aus dem Maschinenbau vol. Band 389

FAU University Press ein Imprint der Universität Erlangen-Nürnberg Erlangen-Nürnberg Lehrstuhl für Fertigungsautomatisierung und Produktionssystematik (FAPS)

  • 2022 (2022)
Contribution
  • Nikolaus Urban
  • C. Vogel
  • T. Brunner
  • Ludwig Gansauge

Collaborative Electromechanical Engineering: A Concept to Overcome Domain- and IT-System Borders.

In: 2024 14th International Electric Drives Production Conference (EDPC). pg. 127-134

IEEE

  • (2024)