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The quality assurance of additively manufactured components poses a particular challenge. The design flexibility of the process makes it possible to create any free-form surfaces or internal geometry elements. Against this backdrop, cost-effective...

Hot bulk metal forming places special demands on process monitoring due to high energy inputs and short cycle times. A multi-sensory method is presented that synchronously records structure-borne and airborne sound signals, decomposes them into...

The production of circular connectors must combine ecological sustainability with high productivity. Cold forging offers almost complete material utilization compared to currently used machining processes and significantly reduces the CO₂...

In bulk forming processes, the contact conditions are inhomogeneously distributed and change throughout the process, resulting in local variations of lubrication. However, current friction models assume constant lubricant behaviour, whereby...

To reduce friction and wear during the forming of aluminum sheet, tool surfaces made of a cast material (EN-GJS-700–2) were chemically oxidized and electrochemically phosphated. The phosphated coatings reduced the coefficient of friction by up to...

Particularly important for increasing the resource efficiency of technical components are not only lightweight design but also innovative manufacturing technologies, and process chains with closed material cycles. Using the example of a demonstrator...

Different material properties may induce slight deviations in surface condition, component temperature, and friction surface and thus significantly impair the bond of rotary friction welded steel-aluminium alloy joints. The effects of different...

Broaching is a key technology for manufacturing the safety-critical connection between turbine disk and blade. While offering, for instance, high process stability, geometric accuracy and productivity, these advantages are offset by high tool costs...

A process for analysing the manufacturability of stress-adapted components made of metal and fibre-reinforced hybrid structures using an industrial robot is being investigated. The use of an industrial robot makes it possible to circumvent previous...

Thin-walled precision components including bipolar and electrolyzer plates are key to the transformation towards sustainable energy usage and storage. Conventional forming technologies for these metallic components, however, are limited in...

A newly developed test setup enables the experimental-numerical determination of the effective heat transfer coefficient (HTC) depending on various influences for the forging of EN AW-6082. The HTC was determined as a function of temperature,...

Carbon fiber reinforced plastics (CFRP) are being applied in a wider range of industrial fields. They are not only used for free-formed surfaces, but increasingly also for profiles, tubes, and bars. When cutting other materials to length, such as...

Implementing AI in manufacturing does not necessarily fail because of model creation but is often due to a lack of reliable operation within production environments. AI Asset Management for Manufacturing (AIM4M) is a process model for the AI...

This article presents a methodology for autonomous cyber defence in Industry 4.0 environments, linking organisational risk management with generative AI. Combining LLMs, RAG, and standardised SOPs creates, a structured decision-making process that...

Sustainable industrial manufacturing can be significantly enhanced using data-driven, AI-supported systems. This paper presents a platform based on the three Zero³ dimensions: Zero Human Potential Loss, Zero Resource Loss, and Zero Data Loss. Using...

In production engineering, CNC-controlled manufacturing cells are increasingly extended to include CNC-controlled robots. However, CNC controllers do not provide functions for planning collision-free motion paths. The Robot Operating System (ROS)...

The paper introduces the “One Stop Autonomization” approach, based on embodied, generative AI agents. These humanoid robots act flexibly in real-world environments, enabling scalable, safe, and human-centric automation. Emphasis is placed on...

Disruptive trends such as digitalization or the sustainability transition are changing the requirements for product portfolio management. This paper develops a reference model and evaluation method that integrates financial and qualitative factors....

Data from CAE-based vehicle development enables planning, validation, and execution of automated disassembly and sorting according to R-strategies (reuse, recycle, recover, etc.). This paper addresses automated disassembly simulation, based on...

Large Language Models (LLMs) have quickly become a central component of digital transformation. While their use is widespread in customer service, marketing and sales, the question arises as to what potential LLMs offer in the production...

Similar to other sectors, the manufacturing industry in Germany is faced by challenges. They include a shortage of skilled labor, rapid advancements in value creation systems, demographic shifts, and an increased willingness to change jobs. This...

The validation of product characteristics is a key success factor in the development of increasingly software-driven systems. An incomplete requirements elicitation is one of the main causes of development errors and product recalls. An integrated...

As an energy carrier, green hydrogen will play a central role in the decarbonization of high-emission sectors. There are potential synergy effects for the technologies required that have not yet been sufficiently researched and utilized. Using the...

This article presents a mobile assistance system for communication and interaction in heterogeneous assembly tasks in SMEs. The assistance system was iteratively developed as a prototype tablet app with the involvement of assembly workers from two...

Hairpin technology has established itself as the standard for electric drives due to the possibility of substituting stochastic winding and drawing-in processes with deterministic forming and assembly processes. At the same time, the technology is...

This study investigates the feasibility of various classification algorithms for real-time, machine-independent instability detection in milling processes. Based on 136 measurements with 5.6 million data points, two new classification methods are...

The assessment of battery condition, from the overall system to the cell level, remains a challenge, particularly outside the laboratory environment. The aging mechanisms occurring within the cell are intricately superimposed, making a clear...