New developments in machining technologies

Resource conservation is continuing to be a main task of society. It requires an increase in resource efficiency in production processes as well as during product operations. The challenges for mechanical machining rise due to trends of difficult-to-machine materials and improved qualities of components and surfaces. This contribution presents new developments of production technology. The focus lies on new machine concepts, including monitoring and simulation of machining processes, resulting in increasing machine availability and process stability as well as in the reduction of primary processing times and secondary times. Innovative machining strategies are discussed, for example 5-axis machining and tribological optimization by preventive out-of-round machining. In addition, CNC functionalities are discussed with respect to monitoring or prevention of collisions. Furthermore the development of hybrid machining processes is emphasized, especially media-superimposed machining. Using hybrid cooling strategies such as high pressure flushing, cryogenic cooling, aerosol and MQL offers the potential to extend profitability and energy efficiency combined with high performance and improved surface integrity. The presentation introduces fundamental functionalities and relationships that characterize the efficient utilization of various cooling strategies. Based on fundamental investigations conducted using high-temperature alloys with poor machinability such as Titanium alloys and Inconel 718, relevant influencing parameters are derived and optimization options are presented for the cooling strategies.