Hybrid cutting processes - potentials of processing strategies with superimposed axis movements

The main goal in manufacturing is to minimize production time, costs, energy and resources while maintaining or even improving performance. For this reason and because of the increase of highly engineered products with complex components and advanced materials, there is a high innovation pressure in the production industry. High performance in production and an increase in energy and resource efficiency can be realized by applying hybrid processes with an integration of additional physical processes and forms of energy into the processing zone. Starting from characteristics of components and materials, this paper shows a classification of hybrid cutting processes and presents a selection of applications at Fraunhofer IWU in detail. A strong focus is placed on hybrid cutting processes with superimposed axis movements and their potentials. The paper shows different kinds of hybrid cutting processes with their specific motivations such as the reduction of thermo-mechanical tool load, the realization of the machinability of advanced materials or the manufacturing of complex geometries. The examples for vibration-assisted cutting processes show that additional axial tool vibrations in the micron range have a positive impact on chip breaking and cutting forces and, consequently, on tool wear and tool. The considered media-assisted cutting processes clarified that the performance depends not only on optimum cutting speed, but also on the combination with the appropriate flushing strategy. Machining with superimposed axis movements enables high-precision manufacturing with new geometrical degrees of freedom. In general, hybrid cutting processes enhance performance for manufacturing and service life of highly engineered products.