Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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Measurement of tool temperatures in the tool-chip contact region by embedded thin film thermocouples

2010 , Kurz, M. , Geisert, C. , Oberschmidt, D. , Werschmoeller, D. , Uhlmann, E.

Monitoring and controlling thermo-mechanical parameters in the tooling material are imperative for improving the fundamental process understanding, assuring the reliability and meeting the desired workpiece quality of material removal processes. Polycrystalline cubic boron nitride (PCBN) tools are being used heavily in machining of low carbon steel and superalloys. These processes are very sensitive to variation in local machining conditions and lack a thorough understanding of fundamental thermo-mechanical phenomena. Existing sensors to monitor machining temperatures are not suitable for process control as they are either destructively embedded and/or don't possess the necessary spatial and temporal resolution. This paper presents an approach for assessing temperature data from the close vicinity of the tool cutting edge. For this purpose an array of 9 micro thin film thermocouple sensors, fabricated using standard microfabrication methods, has been embedded into PCBN using a modified diffusion bonding technique. Experiments were performed for assessing tool temperatures under the rake face of the tool and correlating these measurements to cutting force and vibration signatures.

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Machine-integrated measurement of specular free-formed surfaces using phase-measuring deflectometry

2009 , Richter, C. , Kurz, M. , Knauer, M.C. , Faber, C. , Olesch, E. , Häusler, G. , Oberschmidt, D. , Eßmann, J. , Uhlmann, E.

The authors present first results of a project with the long-term goal of performing optical measurements of ultra precision turned objects within the turning machine. Whereas ultra precision turning machines facilitate the manufacturing of optical free-formed parts, the task of measuring these objects is not yet solved satisfactorily. Moreover, an optical measurement within the machine would be of great advantage concerning a possible feedback to the turning process. Phase-measuring deflectometry has the potential to solve these tasks, but the system has to be adapted to provide the necessary dynamic range and to cope with the limited installation space within the system. We present measuring results of ultra precise turned parts manufactured on a 5-axis ultra precision machine. The surface of these objects displays a local slope up to 30. Furthermore, the potential for future integration of such a measurement system into an ultra precision lathe is demonstrated.

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Kompensieren heißt Fehler vermeiden

2007 , Hohwieler, E. , Kurz, M. , Essmann, J. , Oberschmidt, D.

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