Applications of energy saving in machine tools

Reducing processing times and increasing manufacturing precision are as important in the cost-efficient manufacture of tools as they are for the highly productive mass manufacture of components. The identification and implementation of the subsequent requirements, as far as the machine tool and its main sub-assemblies are concerned, represent a central focus of work at Fraunhofer IWU. These include increased acceleration and higher feed axis speed, increasing the speed for HSC (high speed cutting) and machining operations, and self-optimizing precision control and re-configurability. When it comes to archiving high dynamics, the most important factor is maintaining small loads. This objective can be realized both by applying new structural principles to the machines and through the use of lightweight design techniques - for example, by using metal foams. Components can be integrated into control systems to improve accuracy. The institute is developing methods and tools for systematically designing and optimizing parallel kinematic machines. Approaches to improving energy and resource efficiency involve switching to minimum quantity lubrication or dry machining, and using near-net-shape processes in conjunction with precision machining methods.