Fraunhofer-Institut für Produktionsanlagen und Konstruktionstechnik IPK

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  • Publication
    Micro-texture dependent temperature distribution of CVD diamond thick film cutting tools during turning of Ti-6Al-4V
    ( 2022)
    Uhlmann, Eckart
    ;
    Schröter, D.
    ;
    Gärtner, Eric
    Machining titanium alloys such as Ti-6Al-4V results in a high thermomechanical load on cutting tools and consequently short tool lifes. With respect to a necessary reduction of the resulting cutting tool temperatures, ultrashort pulse (USP) laser fabricated micro-textured rake faces offer direct supply of cooling lubricant into the cutting zone and lead to a reduced heat induction. As a result, micro-textured CVD diamond thick film cutting tools are also capable of machining high-performance materials due to reduced contact temperatures. In the scope of the research, the resulting temperature distribution for micro-textured rake faces will be compared under both dry and wet process conditions. Measurements show a reduction of the resulting cutting tool temperatures of Δϑt = 27.9 % using micro-textured cutting tools compared to non-textured cutting tools. A validated simulation provides valuable information about the contact temperatures enabling a specific development of the micro-texture geometry. As a result, a reduction of the contact temperature between chip and rake face by ΔϑT = 24.7 % was possible.
  • Publication
    Prediction of temperature distribution in diamond cutting tools during machining Ti-6Al-4V
    ( 2021)
    Uhlmann, Eckart
    ;
    Schröter, D.
    ;
    Wohlfahrt, V. H.
    The high thermal conductivity and wear resistance of CVD diamond provide potential for the machining of Ti-6Al-4V. By predicting thermomechanical loads, simulations can provide information about the usability of these cutting materials. However, the occurring shear chip formation within the cutting process leads to unsteady contact conditions. Therefore, a computationally intensive long-term transient simulation is necessary for precise prediction of tool temperatures. In this respect, a user-subroutine has been developed, allowing a high-resolution long-term simulation with acceptable computing time. By experimental investigations and validation of simulated results, a modelling of temperature distribution within the cutting tool is possible, providing valuable information regarding the contact temperatures.
  • Publication
    Mikrostrukturierte CVD-Diamant-Werkzeuge
    ( 2019)
    Bachmann, H.
    ;
    Meier, P.
    ;
    Uhlmann, E.
    ;
    Schröter, D.
  • Publication
    Investigation of wear resistance of coated PcBN turning tools for hard machining
    ( 2018)
    Uhlmann, E.
    ;
    Riemer, H.
    ;
    Schröter, D.
    ;
    Henze, S.
    ;
    Sammler, F.
    ;
    Barthelmä, F.
    ;
    Frank, H.
    The machining of steels with a hardness of 50 HRC and above was in the past primarily only possible with grinding processes. Since the application of cutting inserts made of polycrystalline cubic boron nitride (PcBN), hard turning as a production process with higher material removal rates has established as an economic alternative or supplement to grinding. The increasing number of materials with difficult machining characteristics requires a further development of cutting tools. Physical Vapor Deposition (PVD) coatings lead to an increase of wear resistance, but have thus for not been studied on PcBN substrates. In this contribution, different hard coatings were deposited on PcBN cutting inserts. To identify wear resistance of the coating systems tribological investigations and cutting tests were performed. Furthermore, simulations for evaluation of the coatings as a thermal barrier have been carried out. For the verification of the simulation results, temperature measurements in the cutting process were performed. Based on these investigations the wear behavior of the different coating systems has been analyzed.
  • Publication
    Substitution of Coolant by Using a Closed Internally Cooled Milling Tool
    ( 2017)
    Uhlmann, E.
    ;
    Riemer, H.
    ;
    Schröter, D.
    ;
    Sammler, F.
    ;
    Richarz, S.
    The saving of raw materials plays a major role in industry and is becoming increasingly important. In the field of cutting technology, the aim is to maximise practices such as the substitution of coolant and the steady increase of tool life in order to make an effective contribution towards environmental protection. Concerning the saving of coolant and to enhance the performance in dry machining a milling tool with a closed internally cooled system was developed. Heatpipes are applied which ensure improved heat dissipation from the cutting edge because of their excellent thermal conductivity. The dissipated heat is subsequently delivered to the surroundings via a heat sink. This contribution describes how the performance of a standard tool can be enhanced by the integration of a closed internally cooled system. Simulations of the heat distribution in the tool have been conducted to design and optimise the prototype. Hence, milling tests on duplex steel and temperature measurements in the cutting process have been carried out to verify and further optimise these simulation results.
  • Publication
    Entwicklung und Einsatz eines geschlossen-innengekühlten Fräswerkzeugs
    ( 2016)
    Uhlmann, E.
    ;
    Riemer, H.
    ;
    Schröter, D.
    Auf Grundlage von Entwicklungs- und Konstruktionsrichtlinien wurde ein geschlossenes Innenkühlungssystem unter Einsatz von Heatpipes ausgelegt. Anhand von Simulationsmodellen konnte weiterhin eine Kühlkörpergeometrie definiert werden, die die Kühlleistung optimiert. Zudem wurden simulative Untersuchungen der Temperaturgradienten auf Grundlage eingebrachter Wärmemengen durchgeführt. Die Betrachtung des vorliegenden Zerspanprozesses lässt eine alleinige stationäre Simulation nicht zu, sodass eine rechenintensivere instationäre Lösung zum Einsatz kam, bei der die zyklische Belastung der Schneide berücksichtigt wurde und somit ein realitätsnäheres Ergebnis erreicht werden konnte. Die experimentellen Zerspanuntersuchungen an dem Duplex-Stahl (X2CrNiMoN22 - 5 - 3) haben gezeigt, dass zwischen ungekühltem und gekühltem Prozess ein Temperaturunterschied von 15 Prozent vorliegt und eine Steigerung der Produktivität durch Einsatz eines innengekühlten Fräsers möglich ist. Es wurden unterschiedliche Parametersätze miteinander verglichen und der resultierende Verschleiß aufgenommen. Es konnte mit dem Prototyp, bei gleicher Verschleißmarkenbreite, eine Steigerung der Standzeit von 50 Prozent erreicht werden. Das lässt darauf schließen, dass mithilfe des innengekühlten Fräswerkzeugs eine kostengünstige, energie- und ressourcenschonende Lösungsvariante gefunden wurde, mit der auch eine Steigerung der Prozessparameter möglich ist.