Matthias Weigold

Matthias Weigold
Technische Universität Darmstadt | TU · Department of Mechanical Engineering (Dept.16)

About

115
Publications
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227
Citations

Publications

Publications (115)
Article
Full-text available
In this contribution an analytical approach for estimating the tapping tool’s instantaneous eigenfrequencies of flexural modes is derived. A sensor-integrated tap holder with a close-to-tool vibration sensor attached on the tapping tool is introduced and verified by means of frequency response analysis. The close-to-tool vibration data measured dur...
Article
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Energy optimization of factory operations has gained increasing importance over recent years since it is understood as one way to counteract climate change. At the same time, the number of research teams working on energy-optimized factory operations has also increased. While many tools are useful in this area, our team has recognized the importanc...
Article
As manufacturing companies around the world face the challenge of reducing CO2 emissions and achieving their climate goals, increasing energy efficiency provides a promising solution while potentially reducing costs. Hydraulic systems are used in a wide range of applications such as heating, ventilation, air conditioning or machine tools and accoun...
Article
Due to the massive expansion of renewable energies and the growing importance of carbon pricing, energy prices are rising, and industrial companies must put higher effort in purchasing electrical energy cost-efficiently. Additionally, the increasing share of renewable energies leads to more volatility in the power market, giving companies the oppor...
Article
Crises lead to adverse effects in the value creation ecosystem. In the long term, they lead to uncertainties that can destabilize the system. Resilience is getting more and more critical in connected, value-added ecosystems. Crises such as the Corona pandemic, the Suez Canal blockage, the chip crisis, and rising energy prices can cause sudden chang...
Article
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Due to the high share of industry in total electricity consumption, industrial demand-side management can make a relevant contribution to the stability of power systems. At the same time, companies get the opportunity to reduce their electricity procurement costs by taking advantage of increasingly fluctuating prices on short-term electricity marke...
Article
Due to the increasing supply of volatile renewable energy, demand side management on the consumer side by temporally shifting electrical power demand is needed. Industrial cooling systems in particular offer great energy-flexibility potential since cooling energy is mostly electrically generated and almost all cooling systems already have thermal e...
Article
Machine tools are increasingly being equipped with edge computing solutions to record internal drive signals with high frequency. A large amount of available data may be used to develop new data-driven approaches to process optimization and quality monitoring. This paper presents a new approach to predict the quality of finished workpieces for thre...
Article
Additive manufacturing, in particular the powder bed fusion of metals using a laser beam, has a wide range of possible technical applications. Especially for safety-critical applications, a quality assurance of the components is indispensable. However, time-consuming and costly quality assurance measures, such as computer tomography, represent a ba...
Article
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To make powder bed fusion (PBF) via laser beam (-LB) for metals (/M) available for highly regulated components such as pressure equipment according to the Pressure Equipment Directive, system-specific qualification methods need to be established to deal with process- and geometry-dependent inhomogeneous material behavior. Therefore, the material pr...
Article
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In the context of the ongoing climate change and increasingly strict climate goals of the European Green Deal, industry faces a growing challenge to decrease its high demand for electrical energy and its greenhouse gas emissions. Demand-Side Integration measures have a great potential to reduce the greenhouse gas emissions of the industrial sector....
Article
Companies and nations are developing strategies to reduce CO2 emissions and achieve their climate goals. Due to their high share of final energy demand, heating and cooling supply systems are of crucial importance regarding emission reduction. Here, especially the industrial and building sector have a dominating influence, accounting for 34% and 33...
Article
Industrial cooling supply systems represent an essential component of many industrial production systems. Since these systems are responsible for a significant share of the final energy consumption of the industrial sector, the successful implementation of suitable energy efficiency measures can not only save costs, but also significantly reduce th...
Article
Since the share of renewable energy continues to grow, the resulting fluctuations of energy supply in the electricity grid must be balanced. Electricity consumers can help achieving this by reacting to fluctuations in supply and adjusting their demand (demand response). As one of the largest electricity consumers, industry should embrace this oppor...
Article
Laser-based powder bed fusion as an additive manufacturing process allows the integration of sensors at any location within the manufactured part. This allows for manufacturing smart parts that can be integrated into complex structures for monitoring applications, as they can perform in-situ measurements. Especially, monitoring of force and torque...
Article
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Laser powder bed fusion (LPBF) has indisputable advantages when designing new components with complex geometries due to toolless manufacturing and the ability to manufacture components with undercuts. However, fatigue properties rely heavily on the surface condition. In this work, in-process surface parameters (three differing contour parameter set...
Article
Within the German industrial sector, more than 70 % of final energy is used to supply processes with thermal energy. Nonetheless within manufacturing systems substantial quantities of heat are released as low exergy waste heat due to technical and organizational barriers. This paper presents a concept and digital twin model for an industrial heat t...
Article
The optimization of production processes is even in 2021 still an up-to-date topic, where the use of data is discussed, and the utilization has proven to be effective in specific applications in the last 10 years. Despite increasing access to information directly from the production process and more available computing resources, the data still hol...
Article
The increasing availability of data recording solutions in the field of machining in combination with major developments in Machine Learning and Artificial Intelligence enable new approaches towards optimization in the industrial environment. In the aviation industry, critical components must fulfil extremely high quality standards. This requires a...
Article
Circular shallow recess bearings generate a not rotationally symmetrical pressure profile if they are not aligned parallel. The throttling effect of the shallow recess makes this response possible. Furthermore, the generated pressure profile acts against the tilting. As a result, a shallow recess bearing generates a tilting stiffness. This article...
Article
The ongoing climate change and increasingly strict climate goals of the European Union demand decisive action in all sectors. Especially in manufacturing industry, demand response measures have a high potential to balance the industrial electricity consumption with the increasingly volatile electricity supply from renewable sources. This work aims...
Article
The production of shape accurate forming dies in the toolmaking industry requires a high degree of manual labour. To achieve a higher level of automation, machine-based approaches are necessary. Therefore, robot-based milling experiments of difficult-to-machine cold work steel 1.2379 are carried out. This paper presents an experimental study of dif...
Article
To fulfill service life and integrity requirements when using a non-conventional process in aerospace industry, a comprehensive validation needs to be carried out. According to the state of the art, the characteristically resulting recast layer of wire electrical discharge machining (WEDM) can be reduced to a few microns. To meet existing requireme...
Article
In the context of increasing digitalization, machine tools have a decisive impact on the manufacturing of technically sophisticated products. The resulting large amount of available data opens up new opportunities for process monitoring and optimization. In this paper, a new in-process tool condition monitoring (TCM) approach for end mills is devel...
Article
Approaches to detect energy efficiency measures are associated with time consuming analysis requiring expertise. Against this background, this paper presents an expert system to identify potentials for improving the energy efficiency of metal cutting machine tools based on measurement and meta data of 35 machines. For this purpose, it is necessary...
Article
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The tapping process is one of the most widespread manufacturing processes for internal threads, usually carried out at the end of the value chain. Any non-compliance with required quality standards or even the destruction of the thread due to process uncertainty in the tapping process is therefore subjected to high rework costs. Possible process un...
Chapter
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This chapter describes the various approaches to analyse, quantify and evaluate uncertainty along the phases of the product life cycle. It is based on the previous chapters that introduce a consistent classification of uncertainty and a holistic approach to master the uncertainty of technical systems in mechanical engineering. Here, the following t...
Chapter
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Uncertainty affects all phases of the product life cycle of technical systems, from design and production to their usage, even beyond the phase boundaries. Its identification, analysis and representation are discussed in the previous chapter. Based on the gained knowledge, our specific approach on mastering uncertainty can be applied. These approac...
Chapter
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This chapter describes three general strategies to master uncertainty in technical systems: robustness, flexibility and resilience. It builds on the previous chapters about methods to analyse and identify uncertainty and may rely on the availability of technologies for particular systems, such as active components. Robustness aims for the design of...
Conference Paper
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In modern toolmaking, new manufacturing techniques are being researched and integrated into the production process to increase flexibility and reduce tool manufacturing costs. Thus, the Laser Direct Energy Deposition (L-DED) process was already established as versatile additive manufacturing method for geometry modifications and repairs of press to...
Conference Paper
Towards greener production, manufacturing companies face several challenges, for example peak load shaving or flexible production planning as parts of demand-side management (DSM). DSM uses processes that can be shut down, shifted, or controlled. Advances in digitalization in the energy sector and manufacturing systems create transparency which in...
Article
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Nations and companies are forced to reduce CO2 emissions and decelerate global warming. In this development, the transition of the heating sector is still in its infancy despite the relatively large share of thermal energy in the total energy consumption. Industrial companies can contribute significantly to reduce CO2 emissions by using waste heat...
Chapter
Predictive maintenance of machines promises their operators the possibility of avoiding unexpected machine defects and thus, of increasing the availability of their plants. High expectations of the potential of predictive maintenance have drawn both users and suppliers of machines and systems to deal intensively with the subject. However, only a fe...
Chapter
Pay-per-use models for machine tools based on the operating hours neither include the load nor the actual wear of components, although the machining process has a strong impact on the wear of components and consequently on the residual value of the machine tool. This requires a characteristic indicator for the implementation of stress-based data dr...
Chapter
Advances in digitisation bring new potentials for process analytics and optimisation in machining. New edge-level data acquisition systems provide high-frequent data streams from machine tools. This raw data needs to be preprocessed, structured, and enriched with domain-specific context to become usable information and ready for analyses. Generally...
Article
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The direct use of an advanced binder‐free additive manufacturing technique, namely laser powder bed fusion (L‐PBF), does not easily allow obtaining variously shaped, fully dense Nd–Fe–B magnets with high coercivity. The process inherently leads to the re‐melting of the powder and appearance/disappearance of undesired/desired microstructural feature...
Conference Paper
Production companies face the challenge of reducing energy costs and carbon emissions while achieving the logistical objectives at the same time. Active management of electricity demand, also known as Demand Side Management (DSM) or Energy Flexibility (EF), has been recognized as an effective approach to minimize energy procurement costs for exampl...
Article
Die Bedeutung der Bauteiltrocknung wächst mit steigenden Qualitätsanforderungen im metallverarbeitenden Gewerbe. Damit wächst das Erfordernis, den Energiebedarf von Trocknungsprozessen zu reduzieren. Im Forschungsprojekt LoTuS wird mit verschiedenen Ansätzen die Gestaltung einer Durchlaufreinigungsanlage mit energieeffizientem Trocknungsprozess ang...
Article
This paper presents a method for data- and model-driven control optimisation for industrial energy supply systems (IESS) by means of deep reinforcement learning (DRL). The method consists of five steps, including system boundary definition and data accumulation, system modelling and validation, implementation of DRL algorithms, performance comparis...
Chapter
Tapping is a challenging process at the end of the value chain. Hence, tool failure is associated with rejected components or expensive rework. For modelling the tapping process we choose a mechanistic approach. In the present work, we focus on the tool model, which describes the deflection and inclination of the tool as a result of the radial forc...
Article
Because of the enormous potential of Laser Direct Energy Deposition (L-DED) regarding the production and maintenance of components with complex geometries, this type of Additive Manufacturing processes is of great industrial and scientific interest. As two principals of L-DED, i.e., wire-based (L-DED-W) and powder-based (L-DED-P) processes, are com...
Article
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en The scandium modified aluminium alloy Scalmalloy® is specifically developed for the use in laser-based powder bed fusion (PBF-LB). It is supposed to show potential in the production of lightweight structures due to its high specific strength compared to other aluminium alloys. A limiting factor is the high surface roughness of additively manufac...
Article
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The increasing share of volatile, renewable energies, such as wind and solar power, leads to challenges in the stabilization of power grids and requires more flexibility in future energy systems. This article addresses the flexibilization of the consumer side and presents a simulation-based method for the technical and economic investigation of ene...
Article
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In the context of the European Green Deal, the manufacturing industry faces environmental challenges due to its high demand for electrical energy. Thus, measures for improving the energy efficiency or flexibility are applied to address this problem in the manufacturing industry. In order to quantify energy efficiency or flexibility potentials, it i...
Article
Zur Steigerung der Energieeffizienz stehen Unternehmen des produzierenden Gewerbes verschiedene Maßnahmen zur Umsetzung zur Verfügung. Trotz einer hohen Anzahl möglicher Maßnahmen ist die Umsetzungsrate gering. Die Kenntnis von positiv wirkenden organisationalen Einflussfaktoren kann zur Realisierung von Energieeffizienzmaßnahmen unter dem Aspekt d...
Chapter
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One central aspect of future high speed machining is the knowledge of the thermal behaviour of the machine tool and its motor spindle. A new temperature control for motor spindles with energy efficient synchronous reluctance drive is developed. In the first instance a finite element method model (FEM) is set up. This FEM aims to analyse the use cas...
Chapter
We present a disruptive method for manufacturing structure-integrated force sensors based on the LPBF process by inserting a strain sensing steel plate in the additive manufacturing process of the deformation element. In order to investigate the strain transmission from the printed part to the integrated steel plate, we built two prototypes which d...
Article
Profilnuten in Hochdruckturbinenscheiben gehören typischerweise zu den lebensdauerbegrenzenden Merkmalen eines Flugzeugtriebwerks. Um diese Nuten unter Einsatz eines unkonventionellen Verfahrens, wie dem WEDM, herzustellen und dabei die Lebensdauer- und Festigkeitsanforderungen in der Luftfahrtindustrie zu erfüllen, ist eine umfangreiche Validierun...
Article
Im Forschungsprojekt „TensorMill“ wird die Umsetzung einer intelligent vernetzten autonomen Fertigung von sicherheitsrelevanten Bauteilen in der Luftfahrtindustrie angestrebt. Dabei soll mithilfe von Künstlicher Intelligenz (KI) auf möglichst viele Situationen im Fertigungsprozess reagiert werden. Dies dient dem Ziel, die Produktivität und Prozesss...
Article
Im Rahmen des Projekts LoTuS wird die Bauteiltrocknung untersucht und hinsichtlich der Energieeffizienz optimiert. Zu diesem Zweck wird eine energieeffiziente Durchlaufreinigungsanlage als Forschungsanlage entwickelt und in Betrieb genommen. Zur Steigerung der Energieeffizienz wird eine Wärmerückgewinnung aus verschiedenen Anlagenkomponenten und de...
Article
Die zunehmende Digitalisierung von Werkzeugmaschinen erlaubt neue Ansätze zur Überwachung von Zerspanungsprozessen. Speziell beim Gewindebohren kann am Ende der Wertschöpfungskette ein Fehler im Prozess zum Ausschuss des gesamten Bauteils führen. In diesem Beitrag wird ein neuer datengetriebener Ansatz zur Detektion von Fehlern in Gewindebohrprozes...
Article
Im Projekt ETA-Transfer werden Produktionsanlagen sowie die entsprechenden versorgungstechnischen Anlagen hinsichtlich energetischer Optimierungspotenziale untersucht. Bei sieben Unternehmen werden die jeweiligen lufttechnischen Anlagen analysiert. Hierzu werden Mess- und Unternehmensdaten erhoben, um dann mittels Simulationen potenzielle Energieef...
Article
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Approximately 22 % of the total German energy consumption is used to provide thermal energy in the industrial sector. Therefore, energy efficiency measures in this area offer a major lever for decarbonizing the energy system. Central heating networks can achieve high energy efficiency levels through economies of scale, the coupling of efficient tec...
Article
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The energy supply of modern economies is becoming more volatile due to increasing integration of renewable energy sources. This necessitates the implementation of demand response programs for the industrial sector to make it financially worthwhile for companies to make optimum use of renewable electricity. Optimal production scheduling, considering...
Article
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In order to decrease carbon emissions and to address the problem of resource scarcity, the production industry as major consumer of energy and resources is forced to act and increase the resource efficiency of their production lines. However, for production managers it is often hard to determine, how and where to start implementing efficiency measu...
Article
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Transparent energy flows within a factory are the prerequisite for energetic improvements of the involved production machines. With the ongoing digitalization of industrial production, innovative ways of creating energy transparency on the shop floor are emerging. Virtual energy metering points predict the power consumption of a regarded entity and...
Article
Decision-making highly relies on the accuracy and veracity of data. Therefore, redundant data acquisition and fusion has established but lack the ability to handle conflicting data correctly. Especially digital twins, which complement physical products with mathematical models, and contribute to redundancy. Uncertainty propagates through the digita...
Article
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For small and medium sized enterprises in volatile markets the acquisition costs for complex machine tools are a financial challenge. Hence, leasing models are an alternative to credit-financed purchases. New flexible pay-per-x payment models are particularly interesting as they typically better align cost and income. Since the residual value of th...
Article
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Today, most IoT solutions for the production ecosystem stem from trends that first established at the consumer market. Although these concepts have been adapted well in the industrial environment, it led to fragmented solutions that require complex interfaces. With the recent introduction of GAIA-X, it becomes possible to develop platform independe...
Article
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Standard PLC programming language does not allow to use complex algorithms in building automation for the energetic optimization of industrial supply systems. This paper discusses how future building automation systems should be designed for this purpose. An adapted building automation control program is implemented on an industrial PC and evaluate...