Project Area F: Manufacturing Processes

When selecting the manufacturing processes it was ensured to take different principal effects of processes into consideration. Besides processes that are dominated by one (principal) effect of the process (mechanical: subproject (SP) F01, thermal: SP F02, chemical: SP F03), the also relevant thermal-mechanical (SP F05, SP F06, TP F08) and thermal-chemical (SP F07) combinations of effects will be investigated in the CRC. The selection covers a representative field of energy conversion processes and dissipation processes as well. 

Furthermore, the engagement dynamics are of concern, which are especially relevant for processes with thermal-mechanical effects for example grinding (SP F06) and ultrasonic assisted turning (SP F05). The subproject F05 additionally allows for considering geometrical scale effects for the development of process signatures.

The selection shows that with the chosen manufacturing processes practically relevant application areas are covered.

SP F01 – Processes with mechanical impact

The subproject deals with a comprehensive characterization of mechanically induced internal material loads and material modifications caused in manufacturing processes. In this context, the processes deep rolling and grind strengthening are examined. Within this research work the working hypothesis is that the mechanisms for material modifications generated by processes with a predominant mechanical impact are comparable and can therefore be described in a similar way by process signatures which are expected to contribute to function-oriented manufacturing.

The current results in SP F01 are summarized here on one page.

PIs: Dr.-Ing. Daniel Meyer, Prof. Dr.-Ing. habil. Carsten Heinzel

 

 

SP F02 – Processes with thermal impact

The work program contains empirical as well as analytical and numerical research approaches on the basis of the fundamental thermodynamic equations for the development of the process signatures for EDM processes. The implementation of suitable measurement equipment for the high-resolution local and time-based temperature measurement takes place during single and subsequent discharges. Based on this, the resulting workpiece material loads and modifications will be identified experimentally and a holistic simulation of the energy dissipation during the EDM process will finally be derived.

The current results in SP F02 are summarized here on one page.

PI:  Dr.-Ing. Andreas Klink

SP F03 – Processes with chemical impact

The working program consists of both theoretical and experimental research approaches for the analysis and modeling of workpiece material loads and resulting material modifications during the electrochemical machining (ECM). At first, the local chemical reactions will be evaluated and the material removal process as well as the energy dissipation will be simulated on the basis of commercially available software tools. Furthermore, the multi-phase fluid flow in the electrolyte will be examined via high-speed camera analysis and finally a holistic process signature will be derived.

The current results in SP F03 are summarized here on one page.

PI: Dr.-Ing. Andreas Klink

 

SP F05 – Processes with a small scale thermo-mechanical impact in precision cutting

The subproject F05 focuses on systematic precision cutting experiments, e.g. orthogonal turning and milling processes, under high dynamic conditions to analyze the governing mechanisms for surface generation as well as material separation and material modifications at small scales. Besides steel, the investigations will include the cutting of monocrystalline silicon carbide to investigate from the microstructure level to the polycrystalline level. The analyses will provide information of scale effects for the setup of process signatures for processes with thermo-mechanical impact.

The current results in SP F05 are summarized here on one page.

PIs: Prof. Dr.-Ing. habil. Prof. h.c. Dr. h.c. Dr. h.c. Bernhard Karpuschewski, Dr.-Ing. Oltmann Riemer

 

SP F06 – Processes with thermo-mechanical impact – machining with geometrically undefined cutting edges

The goal of the project is the utilization of varied thermo-mechanical loads (strains, temperature and temperature gradients) during grinding and during laser-assisted deep rolling to achieve a defined modification of workpiece material properties and to establish corresponding process signature components. The experimental work and the evolution of process signatures will be supported by modeling and simulation activities to enhance the fundamental understanding regarding the initiated material loads and modifications of the material properties.

The current results in SP F06 are summarized here on one page.

PIs: Dr.-Ing. Daniel Meyer, Prof. Dr.-Ing. habil. Carsten Heinzel

 

 

SP F07 – Processes with thermo-chemical impact

For the chosen laser-based removal processes the effect of the energy input and energy dissipation on the fatigue of test specimens due to the resulting material loads is to be determined by a targeted variation of control and process variables. A major milestone is the determination of the energy components of the thermal and chemical sub-processes that affect the material modifications of the workpiece surface layer. For selected material modifications the fatigue strength of test samples is determined to test the applicability of process signatures to predict the functional behavior of components.

The current results in SP F07 are summarized here on one page.

PIs: Prof. Dr.-Ing. habil. Frank Vollertsen

 

SP F08 – Processes with thermo-mechanical effect - finishing with geomatrically determined cutting edges

The aim of the subproject (SP) F08 is the simulation-based development of process signature components for hard milling. For this purpose, it is necessary to systematically investigate the effect of mechanical and thermal stresses (temperatures, temperature gradients, strains/stresses) on the resulting material modifications (residual stresses, plastic strain, change of phase fractions). The focus is on the effect of multiple stresses (influence of corner radius and tooth feed as well as milling strategy) and the analysis of thermo-mechanical stresses and their effect on the material modifications.

The current results in SP F08 are summarized here on one page.

PIs: Prof. Dr.-Ing. habil. Prof. h.c. Dr. h.c. Dr. h.c. Bernhard Karpuschewski