Benjamin Melde Email & Phone Number

Bochum, North Rhine-Westphalia, Germany

Title: Developing Adaptive CNC Grinding Strategies based on Machine Learning ModelsMotivation: Saving time and money by automation of manufacturing processesKey Achievement: Reduced rework of multiple turbine blades, up to 5 working daysIn-depth description:CNC grinding of turbine blades & vanes has multiple advantages over manual grinding, like shorter cycle times, better reproducibility, and lower heat impact on the material.As Nickel-based superalloys are commonly known as hard-to-machine materials, finding optimal machining parameters is error-prone and time-consuming, if possible.Moreover, describing the process physically is challenging on all length- and time scales.Hence, the development of an ML model that predicts the resulting cutting depth based on the geometry of the part is needed. It will be used backward, that is, it will suggest machining parameters for a given geometry and local cutting depth.Finally, with the complete 3D data of a part, it can be ground optimally to the customer's nominal geometry.

Bochum, Nordrhein-Westfalen, Deutschland

As a working student in the engineering department, I planned and supervised DoE to help investigate and optimize the manufacturing process. I compared these experiments with CFD simulations of the fundamental creation processes, i.e.- Core & Wax Injection Molding- Metal Casting and SolidificationMy main task was developing this simulation tool, in-house and with affiliated companies & institutes. Finally, the simulations were used to investigate existing and new mold designs virtually. This saved the company significant amounts of time and money.Moreover, I prepared X-ray images of wax models with core for a later automated evaluation with AI. I was also in charge of technical communication with the respective software company.

Bochum, Nordrhein-Westfalen, Deutschland

I designed conceptually and created educational content in materials science for high-school and undergraduate students.I used videos and elements of virtual reality to enhance the understanding of fundamental materials testing methods.Also after lockdowns due to COVID-19, virtual learning methods are a crucially important tool for teachers and students. The massive open online course (MOOC) PepperMINT is a free website for anybody interested in educating themselves, organized from the respective university THGA.

Bochum, Nordrhein-Westfalen, Deutschland

I conducted materials tests on metals and plastics, e.g. tensile-tests or chemical analyses, and investigated certain specimens.I collaborated with affiliated industry partners and supported practical courses for undergraduate students.Moreover, I revised the lecture notes for "Materials Science 1" with up-to-date literature.

Bochum, Nordrhein-Westfalen, Deutschland

Title: Simulating Wax Injection Molding to Represent a Filling Study in the Manufacturing of Hollow Cast Turbine Vanes by Investment CastingGrade: 100/100Motivation: Improving process knowledge and developing the simulation tool.Key Achievement: Reduced discrepancies between simulation and experiments to less than1 mm and 5 °CIn-depth description:Within the scope of my bachelor thesis, I investigated the wax model filling of a stage 1 turbine vane with experimental mold-fill studies and CFD simulations.I fine-tuned the simulation parameters such that they precisely matched the experimental results.I conceptualized and developed the metrological and invented the thermal measurement.Subsequently, the production process was changed to the suggestions of the simulation, and further simulations were used to investigate other production processes, ultimately saving time and costs significantly.

Master Of Science - Ms, Materials Science And Simulation

Master Of Science - Ms, Materials Engineering

Bachelor Of Engineering - Be, Angewandte Materialwissenschaften, 1.8

Focus: Metallic Materials

Abitur, 2.1

Focus: Mathematics, Physics