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17th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2017

作者： Uhlmann, E. Oberschmidt, D. Polte, J. Polte, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775107

Binderless-cubic-Boron-Nitride(cBN) from the company SUMITOMO CORPORATION, Itami, Japan, provides the opportunity for direct cutting of steel with ultra-precision quality without additional equipment or coating of the workpiece. This work presents the latest results in the field of ultra-precision machining of hardened stainless steel with binderless-cBN. In this paper the influence of the cutting speed vc, the feed f, the depth of cut ap, and the cooling lubricant on the cutting force Fc is shown for turning the stainless steel STAVAX ESU. The cutting speed, the feed and the depth of cut were varied between 3 m/min ≤ vc ≤ 450 m/min, 0.9 μm ≤ f ≤ 9.7 μm, and 5 μm ≤ ap ≤ 30 μm respectively. As cooling lubricants compressed air and W200SL of the company OPORTET, Duisburg, Germany, with a volumetric flow rate = 1 l/min were used. For measuring the cutting forces Fc the piezoelectric dynamometer MINIDYN 9256C2 from the KISTLER INSTRUMENTE AG, Middlefield, USA, was used. As a result of this work cutting forces Fc ≤ 4.9 N could be observed with an inconstant progression over the varied process parameters.

关键词： Compressed air

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Droplet removal from PVD-coated micro-milling tools with the immersed tumbling process 17

Droplet removal from PVD-coated micro-milling tools with the...

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17th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2017

作者： Uhlmann, E. Kuche, Y. Oberschmidt, D. Polte, J. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775107

The physical vapour deposition (PVD) process is widely used for the coating of cutting tools. The increased hardness and temperature stability permitted a higher cutting speed and longer tool life in comparison to uncoated tools. Within the PVD-process droplets of the target can be deposited on the coated surface. The consequence is an inhomogeneous surface of the cutting tools with an increased surface roughness. In this study, the immersed tumbling process is used for the droplet removal of micro-milling tools. The results show the functionality of the process for the droplet removal depending of the lapping media and process parameters in connection with the amount and size of the droplets.

关键词： Drops

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Wear behaviour of diamond coated micro-milling tools during micro machining 17

Wear behaviour of diamond coated micro-milling tools during ...

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17th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2017

ISBN: (纸本)9780995775107

Graphite electrodes are used in the die sinking process for manufacturing of micro structured tools in the die and mould fabrication. They are machined using the micro-milling process. During the cutting process graphite grains have strong abrasive effects on the cutting edges and lead to high tool wear. Consequences are short path length lc and geometrical errors. One approach to reduce tool wear is the tool coating with diamond. The diamond coating changes the cutting edge micro geometry which has influences on the process behaviour. In this paper, the wear behaviour of micro-milling tools with diameter D = 0.5 mm and different micro geometries is analysed and discussed. The results show better wear behaviour for prepared and coated tools.

关键词： Coatings

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Characterization and optimization of ultra-precision machine tools and processes by time resolved PSD signature of micro/nano structured optical surfaces

Characterization and optimization of ultra-precision machine...

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2017 Spring Topical Meeting on Precision Engineering and Optics: What are the Limits of Precision, and How to Characterize Them?

作者： Uhlmann, Eckart Kühne, Stefan Jagodzinski, Marco Malcher, Markus Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany

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Manufacturing of CVD diamond micro-end mills with electrical discharge machining 17

Manufacturing of CVD diamond micro-end mills with electrical...

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17th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2017

作者： Uhlmann, E. Oberschmidt, D. Polte, M. Polte, J. Schimmelpfennig, T.-M. Börnstein, J. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775107

At state of the art micro-milling tools made of cemented carbide are widely used in industry. Nevertheless, these micro-milling tools suffer from fast and random tool breakage while cutting. To improve the wear behaviour of micro-milling tools new cutting materials have to be established. In this work electrical discharge machining (EDM) for manufacturing of micro-milling tools with cutting edges made of boron doped chemical vapour deposition (bdCVD) diamond were investigated. Wire-EDM and die-sinking-EDM were compared regarding the characteristics of the micro-tool's cutting edges. It could be concluded that the wire-EDM process is suitable for manufacturing of micro-milling tools with cutting edges made of bdCVD diamond. With respect to the elaborated technologies for the wire-EDM process a cutting edge radius rβ = 3.9 μm and for the die-sinking-EDM process a cutting edge radius rβ = 5.4 μm could be measured.

关键词： Milling (machining)

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Dry-EDM milling of micro-scale features with high speed rotating tungsten tube electrodes 17

Dry-EDM milling of micro-scale features with high speed rota...

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17th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2017

作者： Uhlmann, E. Perfilov, I. Schimmelpfennig, T.-M. Schweitzer, L. Yabroudi, S. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775107

Micro electrical discharge milling is an alternative to die-sinking EDM for the machining of three-dimensional micro-structures or cavities with free-form surfaces. An important advantage provided by micro-EDM milling for this purpose is the possibility to use simple pin or tube electrodes with diameters de ≤ 500 μm. This reduces the manufacturing costs of the workpiece and decreases the setup time for positioning electrodes. The high density of conventional dielectric fluids and the resulting small working gap cause a severe contamination of the working gap with particles and as a consequence short-circuits and process instability. The use of gaseous dielectrics, like compressed air, leads to enhancements in the flushing conditions and the cooling of the tool and workpiece electrodes. The gas is injected through the tube electrode under high pressure, resulting in high flow velocities and a removal of melted material from the working gap. A new spindle with a maximum rotation speed of n ≤ 400,000 rpm was developed by the institute for machine tools and Factory Management IWF of the Technische Universität Berlin for the realization of micro dry-EDM milling with tube electrodes. The high speed rotation of the tool electrode stabilizes the process and increases the material removal rate due to better flushing conditions. This paper presents the equipment and machining results of dry-EDM milling of simple micro-scale features.

关键词： Electrodes

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Compensation for tool deformation and expansion in virtual try-outs of hot stamping tools

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IOP Conference Series: Materials Science and Engineering 2018年第1期418卷

作者： Lars Penter Steffen Ihlenfeldt Norbert Pierschel Institute of Machine Tools and Control Engineering TU Dresden Dresden 01062 Germany Fraunhofer Institute for Machine Tools and Forming Technology Chemnitz 09126 Germany

The mechanical properties of hot-stamped parts strongly depend on the tool's cooling performance. The cooling rate hinges on sufficient temperature gradients and on an excellent contact conductance between tool and workpiece. A uniform distribution of the contact pressure is the key to an even cooling behaviour, and hence, a homogenous micro structure of the formed part. Elastic deformations of machine and tool components under load are a major influence on the pressure distribution between tool surface and hot-stamped part. This applies to hot and cold forming tools. An additional difficulty in hot stamping are superimposed thermal expansions and contractions of the tool, which also affect the part's mechanical properties due to their influence on the normal contact pressure. Manual die spotting needs to compensate for all these undesired effects and makes tool try-out a large time and money-consuming factor in the development of hot forming tools. This paper presents methods to transform the spotting of hot forming tools into a virtual production reality in order to reduce manual labour and lower costs. It gives details on the numerical compensation of tool surfaces for elastic tool and machine deformations and for temperature-induced tool expansions and contractions. The authors critically analyse necessary and achievable accuracies of computed surfaces and point out required improvements for the future implementation of virtual try-outs into tool development and manufacturing processes.

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Multi-scale Modelling Approach for Contributing to Reduced Distortion in Parts Made by Laser-based Powder Bed Fusion

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Procedia CIRP 2018年 67卷 197-202页

作者： Christian Seidel Michael F. Zaeh Technical University of Munich Institute for Machine Tools and Industrial Management (iwb) Boltzmannstrasse 15 D-85748 Garching Germany Fraunhofer Research Institution for Casting Composite and Processing Technology IGCV Beim Glaspalast 5 D-86153 Augsburg Germany

Within this paper, a control volume-based multi-scale approach for heat input modelling in laser-based powder bed fusion of metals is described. Thereby, the Rosenthal equation is used to analyse beam-powder interaction for a single laser track. Based on both the Rosenthal results for melt pool dimensions and experimentally determined melt pool depth, a single layer model is developed. Results for the temperature field, gathered by applying the single layer model, serve as data for validating the control volume-based approach on the build-up scale. Finally, a case study with a turbine blade delivers the proof-of-concept for the applied modelling approaches, because process-related distortions are reduced by more than 40% through pre-deforming the blade according to build-up simulation results.

关键词： Additive manufacturing Powder bed fusion Laser beam melting Selective laser melting Simulation Distortion Heat input modelling

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Modeling approach regarding surface functionalization by force-controlled micro and nano forming 17

Modeling approach regarding surface functionalization by for...

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17th International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2017

作者： Uhlmann, E. Kühne, S. Jagodzinski, M. Malcher, M. Trevino, R. Institute for Machine Tools and Factory Management IWF Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology IPK Germany

ISBN: (纸本)9780995775107

Surface functionalization allows the control of fluidic, tribological, biological or optical properties. Suitable processes are interference lithography (IL), ultra-precision machining and micro and nano forming. The force-controlled forming process enables a reproducible production of structures with an absolute height in the double-digit nanometer range. The deformation is a complex process consisting of controlled and uncontrolled material deposition. Knowledge about the uncontrolled behaviour, however, allows a reproducible production of defined structures. A model approach with regard to machining parameter prediction is presented here. The tool shape is transferred into the surface by plastic penetration of a faceted diamond tool. By means of a superimposed tool movement, linear structures can be generated. Larger areas can be structured by repeating this process. The advantage of the force control in comparison to the displacement control is a defined penetration depth relative to the surface with reproducibility in the single-digit nanometer range. The force-control is carried out gravimetrically (0.05 N -1-1, 30 nm 2neg2) is considered as ideal load. As additional result of these experiments, physical approaches are available, which can later form the basis of a physical model.

关键词： Optical properties

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Concept and architecture for programming industrial robots using augmented reality with mobile devices like microsoft holoLens 22

Concept and architecture for programming industrial robots u...

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22nd IEEE International Conference on Emerging Technologies and Factory Automation, ETFA 2017

作者： Guhl, Jan Nguyen, Son Tung Krüger, Jörg Department of Industrial Automation Technology Institute for Machine Tools and Factory Management Technische Universität Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

ISBN: (纸本)9781509065059

This paper proposes a concept for human-robot interaction using techniques of virtual and augmented reality on mobile devices like cell phones and tablets or mixed reality devices like the HoloLens. By combining data received from real robots together with the perception and abilities of a human operator innovative applications are imaginable. Visualizing not only the current robot state but also the robots environment captured with different sensors and processed with both machine and human vision can lead to a rising percentage of robot assisted workplaces or robot installations. Since the visualization of and the interaction with the robotic application is not locally restricted new or improved use cases like remote maintenance or faster startup of industrial robots can be realized. Therefore, an architecture split into three functional units and an overview of our implementation is presented. © 2017 IEEE.

关键词： Human robot interaction

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