Importance of Manufacturing and Research for society needs ... · Importance of Manufacturing and...

LFMLabor für Mikrozerspanung

IWTStiftung Institutfür WerkstofftechnikBremen 1

Importance of Manufacturing and Research for society needs - sustainable, global and local

Prof. Dr.-Ing. habil. Dr.-Ing. E.h. E. Brinksmeier

University of Bremen, Germany

IWT – Stiftung Institut für Werkstofftechnik

Leuven, 4th December 2015

Lecture on the occasion of a ceremony for Prof. J.-P. Kruth having received the 2015 Bower Science Award



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Typical BremenUniversity, Companies and Sights

IWT


IWTStiftung Institutfür WerkstofftechnikBremen

Legal form

Founders

Personnel

Funding

Building/Labs

3

Foundation Institute ofMaterials Science, IWT

Foundation under Private Law (independent institute)

1. AWT-Association for Heat Treatment and Materials Science (about 250 companies as members)

2. Federal State of Bremen

Overall 163 employees (85 scientists and 73 technicians

Approx 20 % primary funding

approx 80 % third party funding (DFG, AiF, BMBF, EU,…)

Approx. 6.700 m²



Process & Chemical Engineering

Manufacturing Technologies

Materials Science

4

Prof. Dr.-Ing.H.-W. Zoch

Prof. Dr.-Ing. habil.L. Mädler

Prof. Dr.-Ing. habil. Dr.-Ing. E.h.E. Brinksmeier

Heat TreatmentSurface EngineeringMechanical PropertiesPhysical AnalysisLightweight MaterialsMetallographic AnalysisTechnology Broker

Reactive SprayingPowder & ParticleMeasurementsMultiphase Flow,Heat & Mass TransferMelt AtomizationSpray Forming

ECO Center for sustainablemanufacturingMaterial Oriented ManufacturingLaboratory forPrecision Machining



Process & Chemical Engineering

Manufacturing Technologies

University of Bremen – Department 04 Production Engineering

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18 lectures2 labs and exercises12 degree theses23 doctoral candidates20 Post-Docs



Materials Science

Founded in 1982Approx 1800 studentsApprox 180 scientists

Scientific education (2015) Scientific education (2015) Scientific education (2015)

Currently 29 professors9 affiliated institutes

Prof. Dr.-Ing.H.-W. Zoch

Prof. Dr.-Ing. habil.L. Mädler

Prof. Dr.-Ing. habil. Dr.-Ing. E.h. E. Brinksmeier



Manufacturing TechnologiesOur groups

High Precision MachiningCutting and Forming

forinnovative

manufacturing technologies

Processes and Surface Integrity

Material orientedManufacturing

7

The International Academy for Production Engineering

Collège International pour la Recherche en Productique

Internationale Akademie für Produktionstechnik

Leuven, December 4th, 2015

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The International Academy for Production Engineering

Members– 450 distinguished researchers (Fellows and Members)

from science and industry– 120 young researchers (Research Affiliates)– Membership is limited to invited and active persons who were

recognized by the academy due to their work

Headquaters– Paris, France

Meetings– CIRP Winter Meetings (February, every year in Paris)– CIRP General Assemblies (August, every year in alternating regions and

countries)– CIRP Conferences (several conferences per year)


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Motivation– French Engineer General Pierre Nicolau:

„To promote the scientific understanding of production engineeringtechnologies in order to increase productivity of manufacturingindustries.”

Founded in 1951 by– E. Bickel (Switzerland),– D.F. Galloway (UK),– P. Nicolau (France), and– O. Peters (Belgium)

Current vision– To promote research and development among its members from

academia and industry to contribute to the global economic growth andwell being of society.

CIRP – Past and Present


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Prof. K. Ueda, JapanCIRP President 2014-2015

Prof. E. Brinksmeier, GermanyCIRP President 2015-2016

CIRP Presidents and General Assemblies




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Outline

1. Short Introduction of IWT/Univ. of Bremen, and CIRP

2. Basic views on manufacturing engineering

3. Manufacturing engineering for needs of society and future markets

3.1 Health3.2 Renewable energy supply3.3 Efficient and sustainable mobility

4. Dimensions of manufacturing – sustainable, global and local

5. Conclusion & OutlookSource: KU Leuven – Rob Stevens

Source: IWT Bremen



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Pioneers of Industrial ProductionRemarkable quotes

“Scientists study the world as it is; engineers create the world that has never been.”

Theodore von Kármán, year is unknown



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Industrial ProductionSpectrum of products

Industrial Production

Services

Immaterial Products

Chemical engineeredmaterial goods

Materialized Products

Manufacturedmaterial goods Intellectual creations

sources: Institution of chemical engineers, ZF, fotolia.com, inventors.com



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Core technologies in industrial productionPrinciples of form generation

Tool

Tool movement

Rotation

Work piece

Controlled Shaping(material removal)

Work piece

Tool movement

Lower die

Upper die

Replication

source: after „Werkzeugmaschinen, Grundlagen”, H.K: Tönshoff; Brinksmeier

Work piece

Tool

Tool movement

Work piece

Controlled Additive Manufacturing

- Casting- Metalforming- Molding

- Turning- Milling Metal Cutting- Drilling

- Rapid prototyping- Selective laser melting/sintering- 3D-Printing



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CNC controlCNC control

Turning machinewith crank handle (Ch. Plumier, 1700)

Turning machinewith crank handle (Ch. Plumier, 1700)

Microtome knivesMicrotome knives

1700 1750 18001900

1950

2015

Manufacturing MilestonesHistorical Development of Production Technology

High-speed steel(F. W. Taylor)

High-speed steel(F. W. Taylor)

1990

Assembly Line Production (Henry Ford)Assembly Line Production (Henry Ford)

Steam Engine (J. Watt)Steam Engine (J. Watt)

1850

First lathe (H. Maudslay)First lathe (H. Maudslay)

Industrial robotUNIMATE (George Devol )

Industrial robotUNIMATE (George Devol )

Additive ManufacturingAdditive Manufacturing

1970

Electric motorElectric motor

CAD/CAM tool path generationCAD/CAM tool path generation

Geometry andmaterial properties(Field, Kahles, Peters et al.)

Geometry andmaterial properties(Field, Kahles, Peters et al.)

Industry 4.0Industry 4.0

19601980……



Manufacturing engineering for needs of society and future markets

sources: after FHG, pictures: melumat.de, Solar Energy World, IWT Bremen

Health Efficient and sustainable mobility

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Renewable energy supply



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Needs of society and future marketsPrecision components for health

source: melumat.de

Health

Society: - health care for extending and improving the quality of life

Example: - eyeglasses

Requirements: - individual lenses- low costs- high quality



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Ophthalmic lenses for eyeglassesManufacturing processes

sources: ADC, Satisloh

Ophthalmic lenses for eyeglasses are generated by precision turning, milling and grinding

Surface finish is performed by different polishing processes

turningmilling polishing Beveling/grinding



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Progressive lens glassesIndividually optimized / customized

sources: Fraunhofer IPT, Aachen

Production of extreme freeform

Reduction of production time < 1 min. per glass

Production without iteration loops

Approx 14 Mio. Freeform progressive lens glasses per year in Germany (2014)

Currently up to 50% growth per year

Over 50% individual progressive lens glasses in the future (90 Mio. pairs per year)

View with individual adapted progressive lens



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Hard Contact lensesManufactured by diamond turning and polishing

sources: Techno-Lens, Menicon, eyenirvaan.com

Contact lenses are manufactured by:

turning and polishing of polymethyl methacrylate (hard)

10% of contact lenses worldwide are hard lenses custom made!

turning polishing Workpiece holder

Contact lens

Polishing tool(covered with slurry)

Slurry

Fixation (with pitch)

Contact lens

Tool



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Soft Contact lensesManufactured by injection molding

sources: Techno-Lens, Menicon, eyenirvaan.com

Liquid monomer is injected into anterior mold

Posterior mold is capped withanterior mold

Liquid monomer hardened throughultra-violet light

90% of contact lenses worldwideare soft lenses mass production!

value of the worldwide contact lens market at approximately $7.6 billion

Upper mold, forms basecurve of lens

Counter mold, forms front curve of lens



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Optical qualityContact lenses and eyeglasses

sources: Zeiss, Issaquah Vision, Reddit, values: Precitech, X-Ram Vision

Hard and soft contact lenses:

Roughness Ra: 8-10 nm

Form accuracy P-V: < 3 µm

Ophthalmic lenses for eyeglasses:

Roughness rms = < 5 nm

Form accuracy P-V = < 5 µm



Customized manufacturing of hearing devices

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Silicone imprint

Scanning Modeling, generationof CAD/CAM data

3D printing(selective lasersintering, Stereolithography)

Installation ofelectronics

source: PHONAK Hüs

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ConclusionImportance of customized manufacturing for health care

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Source: dpa

Customized manufacturing is a big driving force for growing public health: New manufacturing technologies enable

progress in producing medical devices for a longer and more comfortable life, such as

• Ophthalmic lenses• Hearing devices• Prostheses• Implants• Medical instruments• …

Source: Ceramtec

Source: bestezahnimplantate.de

source: melumat.desource: akustikum.de

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Space research

Needs of society and future marketsNew manufacturing technologies for renewable energy supply

sources: Solar Energy World


Society: - using of renewable energies, getting rid of oil-based energies

Example: - wind power plants, solar technique

Requirements: - Research to increase efficiency and lifetime

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Needs of society and future marketsNew manufacturing technologies for renewable energy supplyEuropean Commission – 2030 Energy Strategy:

• At least a 27% share of renewable energy consumption• At least 27% improvement in energy efficiency compared to 1990 levels• A 40% cut in greenhouse gas emissions compared to 1990 levels

Source: European Commission

a. Wind power plants

Requirement: Reliable power train (40% share of failure isrelated to gearboxes)

Need for research in gear failure analysis and manufacturing ofenhanced gears

b. Solar technique

Requirements: High efficiency, low cost

Research needs for solar cells and high precision optics

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sources: Solar Energy World, MDA



Fresnel lenses concentratesunlight 500 times

Focuses sunlight onto small, highly efficient multi-junctionsolar cells

In 2014, a new world recordhas been established:

The newest solar cellsconvert 46% of solar light into electricity

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Fresnel lenses for solar energyConcentrator photovoltaic (CPV) modules

source: Soitec



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Fresnel lensesManufacturing and functional principle

source: lighthouselens.com

Fresnel lense in lighthouse (Fresnel, 1822)

Functional principle of a fresnel lense

Light focusing by a fresnel lense



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Fresnel lenses for solar energyFunctionality of concentrator photovoltaic (CPV) modules

source: Soitec



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Concentrator module of a photovoltaic systemTIR facets



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Solar concentrator with hybrid PMMA lens

Solar cellHeat sink Aspheric lense

Hybrid lenseHybrid lens with total internal reflectionSize: 40 mm x 40 mm625 elements per m2

Mold insert:Diamond turned; material:Nickel on steel substrate



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Manufacturing engineering makes a significant contribution to renewable energies, e.g. within the fields

• Solar technology• Wind power plants

Another challenging field for further research:

• Energy storage

Importance of manufacturing for renewable energy supply

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source: Fotolia.com

source: IWT Bremen

sources: wikimedia, Solar Energy World

source: MDA

Source: Solar Energy World






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Needs of society and future marketsNew manufacturing technologies for efficient and sustainable mobility

sources: IWT Bremen

Efficient and sustainable mobility

Society: - Efficient and sustainable mobility

Examples: - Fine finishing of gears

Requirements: - Research to increase efficiency and lifetime of gearboxes

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Pioneers of Industrial ProductionRemarkable quotes

“There will be built not more than 5000 vehicles in total. The reason is that there are not enough chauffeurs to steer it.”

Gottlieb Daimler, year is unknown



Challenges for power trains:• Reduction of the design space and weight

of gearboxes without lost of transmissible power Resource efficiency

• Reducing the gear noise• Increase energy efficiency and reduce CO2

emissions by reducing the power loss in gearboxes Energy efficiency

Sustainability

Source: Porsche AG

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Gear ProductionNew manufacturing technologies for efficient and sustainable mobility

Global developments of CO2 - Limits :

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Gear Production – Some Figures:

• Sales worldwide: approx. 200 – 250 billion € per year• Produced cars: approx. 70 million per year

• Average: 15 gears per car gearbox• > 1 billion gears per year for car gearboxes

Source: IPPCSource: Hansen Industrial Gearboxes, Antwerpen

Source: ZF



Research in Gear ManufacturingNew manufacturing technologies for efficient and sustainable mobility

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Surface roughness: Shape accuracy: Surface integrity:

Fields of research:

Technology transfer:

Fine finishingof gears withhigh shapeaccuracy:

Sources: IWT Bremen



Research in Gear ManufacturingFine finishing of gears with high shape accuracy

time

tem

pera

ture

geargrinding

heattreatment

deburring, cleaning

softturning

gearhobbing

Standard process chain of gear production:

Demands on gears: reduction of:

• noise emission• weight• Volume

increase of:• torque/power• lifetime

Tasks of gear grinding:• reduction of:

• surface roughness

• increase of: • gear tooth quality

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vibratory finishing(var.)

surf

ace

roug

hnes

s

shape deviation

skive hobbing(IT 6 – 8)

continuous gear grinding(IT 3 – 6)

gear profile grinding(IT 2 – 6)

state after heat treatment

low

high

highlow

fine finishing- down to “near optical”

surface quality

honing(IT 5 – 7)

source: Gleason-Pfauter

Surface roughness and shape deviationdepending on different finishing processes




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Sa = 0.61 µmSz = 3.92 µm

Sa = 0.012 µmSz = 0.081 µm

Fine finishing of gears – Research achievements:

• New 2-step-approach with elastic wheel (2nd Step) leads to highest surface quality:• Sa = 0.012 µm• Sz = 0.081 µm

• Gear tooth quality of preceding finishing can be kept• Low risk of thermal damage• Positive influence on surface integrity (compressive residual stresses)• Applicable on conventional gear grinding machines• Subsequent processes (vibratory finishing, lapping, honing, polishing) can be omitted

a) pre-ground b) fine-finished

Surface roughness before (a) and after (b) fine finishing (WLI measurements):



Conclusion

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Manufacturing engineering provides the technologies to meet future requirements of resource and energy efficiency.

Example:

Gear manufacturing

Very high number of units

Big impact of gears on

• Resource efficiency• Energy efficiency

in mobility

Importance of manufacturing for efficient and sustainable mobility

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Source: IWT Bremen

Source: IWT Bremen

Source: Hansen Industrial Gearboxes, Antwerpen



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Importance of Manufacturing

Manufacturing is still the driving force of the European economy and it provides:

• Creates about 20% of all jobs (more than 30 million)• Largely in SMEs in 25 different industrial sectors

• About 75% of EU exports are related to manufacturing• In manufacturing: over 80% of EU private sector R&D expenditure

Andrea Gentili, “Manufuture”, 2012

European Perspective:



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Categories of Manufactured GoodsLocal Manufacturing matters

About half of all manufacturing occurs

near the customer:

Source: McKinsey, Manufacturing the Future, based on data from IHS Global insight, OECD, ASM 2010



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Manufacturing employment by groupLocal Manufacturing matters

The importance of localmanufacturing continues

to grow:

Source: EU KLEMS; OECD; McKinsey Global Institute analysis



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Competitive Sustainable Local ManufacturingParadigm by Jovane and Seliger

Competitive Sustainable Global Manufacturing paradigm:„Global manufacturing industries constitute factories located in countries with

competitive advantage (tax, labor cost, etc.)”

Competitive Sustainable Local Manufacturing paradigm:„Establishing local manufacturing industries for local customers.”

Motivation: The proximity of the manufacturer to the final customer is critical to product delivery, fit and service.

Local Perspective:



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Competitive Sustainable Local ManufacturingParadigm by Jovane and SeligerCompetitive Sustainable Local Manufacturing paradigm:

„Establishing local manufacturing industries for local customers.”

Consequences:

• Creates local jobs in product design, in the manufacturing of these products and in their service

• Liberated local capability creates new economic momentum based on manufacturing new products, characterized by:

• their need to be tailored to individual buyers• be modified during their lifetime to re-adapt to

changing needs of customers• Requires new manufacturing technologies and a new

generation of manufacturing professionals• “Local manufacturers are more likely to innovate

because of their close proximity to their customers.”

Eyeglasses

Additive Manufacturing

Source: KU Leuven –Rob Stevens

All –in-onedigital surfacingcenter



Additive Manufacturing- a local and sustainable technology

Sustainable Manufacturing“meets the needs of the present without compromising the ability of future generations

to meet their own needs.“

„Manufuture“ Conference 2007

Additive Manufacturing – Potentials:

• Reduced raw material usage and energy consumption, which is a key contribution to environmental sustainability.

• Healthcare products customized to the needs of individual consumers, which is expected to significantly improve population wellbeing.

• On-demand manufacturing, which presents an opportunity to reconfigure the manufacturing supply chain to bring cheaper products to consumers faster while utilizing fewerresources.

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Source: Huang, Liu, Mokasdar, Hou: Additive manufacturing and its societal impact::a literature review, Adv. Manufacturing Technology 67, 2013

Source: KU Leuven – Rob Stevens

Source: Lincoln Electric



… Additive Manufacturing

Manufacturing Engineering provides the basis to be able to cover needs of society in areas such as:

• Health• Renewable energy supply• Efficient and sustainable mobility

The importance of local manufacturing continues to grow:

A competitive sustainable local manufacturing

requires new manufacturing technologies like…

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Conclusion



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Additive ManufacturingAdditive Manufacturing

Source: K

U Leuven –

Rob S

tevens



Thank You Audience, and Congratulations toProf. Jean‐Pierre Kruth!

Thank You Audience, and Congratulations toProf. Jean‐Pierre Kruth!

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