Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Micro-milling of a sprue structure in tungsten carbide-based metal matrix composite
    ( 2021)
    Uhlmann, Eckart
    ;
    Polte, Julian
    ;
    Polte, Mitchel
    ;
    Hein, Christoph
    ;
    Hocke, Toni
    ;
    Jahnke, Christian
    Many industries rely on plastic components manufactured by micro-injection moulding. There is a high potential to further increase the cost-effectiveness by machining the moulds needed for this process from non-ferrous metals and reinforcing the parts of the mould, which experience high loads during the micro-injection moulding. Inserting tungsten carbide particles locally into the surface of these non-ferrous metals is one possibility of reinforcement. The resulting metal-matrix-composites (MMC) exhibit the needed wear resistance, while the ground material can be machined very effectively through micro-milling. In contrast, the Micro-milling of these MMC-materials is challenging and so far not state of the art. Thus, this investigation is concerned with the development and qualification of micro-milling parameters for tungsten carbide-based MMC-materials. Binderless polycrystalline diamond as innovative cutting material was applied for this purpose. The goal of the mil ling parameter development was to optimize the surface roughness and the form accuracy for machining an aluminium bronze workpiece reinforced with tungsten carbide particles through laser injection. Based on an analysis of a wide range of process parameters, an optimised milling strategy was applied to machine a sprue structure from the described MMC-material. Different parameter sets are evaluated by analysing the form accuracy and measuring the surface roughness of machined structures. A surface roughness of Ra = 80 nm and form accuracy of a = 3 µm could be achieved with optimized micro-milling parameters and qualified the developed parameters for industrial applications.
  • Publication
    Tool wear and surface roughness in micro-milling of aluminium and high-alloyed aluminium materials using cutting tools made of binderless carbide
    ( 2021)
    Uhlmann, Eckart
    ;
    Polte, Mitchel
    ;
    Wiesner, H.M.
    ;
    Polte, Julian
    ;
    Hein, Christoph
    Micro-milling can be applied for manufacturing in a wide range of materials and complex geometries. This process is especially important for the aerospace industry. High-alloyed aluminium is a common material for aerospace applications with complex micro- and macro-geometry due to its high wear resistance. The costs-effectiveness of producing these parts can be increased by using tools with improved wear behaviour and higher life times. However, wear-resistant tools are often associated with higher tool costs, which reduces the cost-effectivness of the whole production. An innovative solution is offered by the use of a cutting tool made of binderless tungsten carbide. The micro-milling of conventional and high-alloy aluminium with a new cutting material based on a binderless tungsten carbide is analysed in this investigation. The absence of a binding phase leads to an increased hardness and improves the wear behaviour of these tools. Therefore, tools with a tool diamete r of D = 10 mm were manufactured and there machinability was successfully proven. The feasibility of these innovative tools is demonstrated in a series of experiments. The experimental investigations were carried out on the five-axis high precision machine tool PFM 4024-5D PRIMACON GMBH, Peißenberg, Germany, with a workpiece made of TiAl 48-2-2. A surface roughness of Ra = 0.202 µm was detected after a path length due to primary motion lc = 70 m without any noticeable wear marks on the cutting tool. These results show the economic potential for milling tools based on binderless carbide for achieving high precision surfaces while reaching high lifetimes.
  • Publication
    Manufacturing and replication of sub-10 mm micro-bowls for biomedical sensor systems
    ( 2018)
    Uhlmann, Eckart
    ;
    Hein, Christoph
    ;
    Polte, Mitchel
    ;
    Polte, Julian
    ;
    Dähne, L.
    The technical implementation of a novel biosensor for the highly parallelized screening of biochemical binding reactions depends on the manufacturing of an array of micro-bowls with a diameter dB 10 µm with an aspect ratio ar 1. Since the operating principle of the biosensor is based on the stimulation of stationary optical waves in micro-spheres, micro-bowls for the immobilisation of these spheres in a microfluidic environment are necessary. Due to this operating principle, the micro-bowls need to separate the spheres from the fluid flow and ensure the careful adherence of single spheres, coincidently. Moreover, the pathway for the optical accessibility of the micro spheres should be unrestricted. This work presents a process chain for the manufacturing of microfluidic chips with an array of n 1,000 micro-spheres by ultra-precision milling of mold inserts, the replication by precision injection molding as well as experimental trial results. With regard to manufacturing of the mold inserts, the uniform and burr free ultraprecision milling of large aspect ratio micro posts was investigated within a parametric study. Furthermore, the replication of the micro-bowls was examined by taking the consistent replication of the entire bowl array, the adverse formation of fillets, and the replication of surfaces with optical functions into special account. By the analysis of the microfluidic and optical properties of the replicated structures, the correlation between mold manufacturing, replication, and operating conditions can be performed.
  • Publication
    Manufacturing, replication and assessment of microfluidics for blood plasma separation
    ( 2016)
    Uhlmann, Eckart
    ;
    Hein, Christoph
    ;
    Polte, Mitchel
    ;
    Polte, Julian
    ;
    Spielvogel, Anja
    ;
    Huth-Herms, Katrin
    ;
    Oberschmidt, Dirk
    Point of care diagnostics gain importance with regard to novel diagnostic techniques. Future applications, for example based on cell-free DNA, are prenatal or cancer diagnostics. With regard to these methods a large influence of natural blood degradation during full blood storage and transport before laboratory based separation restricts possible applications. With a point of care plasma separation device, the plasma can be separated from full blood directly after blood collection. Thus, diagnostic markers remain undamaged and allow a highly specific detection. Targeting microfluidics for point-of-care blood plasma separation, this work presents the development of a microfluidic blood plasma separation device along a novel process chain. Besides system design and manufacturing technologies for prototypes, the development of technologies for replication, closure of microfluidics and affecting of surface properties are under the special scope of this investigation.