Low levels of lead are often added to copper alloys in order to improve their machinability. This generally effects longer tool life, improved chip breakage, lower cutting forces and better surface quality. However, legislation more and more tends to prohibit the use of lead in copper alloys, as lead is harmful to the environment and health. Consequently, the machinability deteriorates tremendously, especially with respect to chip break-age and tool wear.
It is the aim to develop a High Performance Cutting (HPC) for machining lead-free copper alloys. In this connection, the material removal rate, process ... More...


 

For many decades free cutting steels, case-hardened steels and quenched and tempered steels were added by small quantities of plump to improve the machinability. Plump leads among other things to the formation of lubricating intermediate layers, which cause a decrease of the tool wear and the total force. Further the chip breakage improves due to the embrittling effect by alloying of plump. The goal of this project was to find out alternatives of plump for ... More...


 

The limited strength of conventional ductile cast iron and the constantly growing requirements on cast parts in combination with the demand on consequent weight reduction, require the use of new materials. An important development is represented by austempered ductile iron (ADI). By a special heat treatment of conventional ductile cast iron a material with particular microstructure is made. This microstructure improves the mechanical properties. A wider industrial use is hindered by a lack of knowledge about machining this material. As capable partner the WZL can hearken back to numerous industrial and research projects... More...


 

Nowadays gray cast iron still represents an adequate material for many products. But if the requirements on strength increase, gray cast iron bows out because of the limited tensile strength. In this case compacted graphite iron is the material of choice. But in past years the increasing material costs and the poor castability expedited the development of new materials. In this development austempered gray iron is of utmost importance. By a special heat treatment a microstructure is generated which is comparable to ADI materials an which causes a clearly higher tensile strength without alloying. But for a wider industrial use the knowledge ... More...


 

Objective of this project ManufacTiAl was to develop adapted tools and process strategies for the high speed turning and milling of TiAl alloys, in which micro crack free machined surfaces are of major importance. Against this background, technological sophisticated and optimized cutting technologies were developed within this research project, which guarantee economic manufacturing of gamma TiAl-blades. Innovative coolant strategies minimum quantity coolant (MQL), which was proven as beneficial in machining intermetallic titanium alloys and the innovative high pressure coolant as well as cryogenic cooling was analysed as coolant strategies. By using high pressure coolant, more heat than in comparison to conventional coolant can be removed out of the shear zone. Hence, tool wear which is traced back to thermal load can be reduced and tool life is enlarged. On the other hand the improved coolant results in ... More...


 

The machining of titanium alloys can be an extremely critical process due to the high thermal and mechanical load on the tools. This is caused by the high temperature strength, the low thermal conductivity and the low Young’s Modulus of titanium alloys. In order to increase the performance of machining processes, the WZL provides support in the selection of adapted lubricoolant strategies for your company's specific needs. With our know-how of many years in the field of innovative lubricoolant strategies we will support ... More...


 

Due to their excellent high temperature properties nickel-base alloys are considered hard to cut materials. Conventional cutting materials such as high speed steel and uncoated cemented carbide only allow the cutting of nickel base alloys at low cutting speeds, which yield to long process durations and accordingly high costs. In contrast, ceramics and CBN as cutting materials enable cutting speeds of up to 600 m/min for roughing and finishing and therefore help to reduce the manufacturing costs while keeping a high tool life and part quality. ... More...


 

The ever increasing need for light weight components explains the increasing industrial interest in machining of carbon-fiber-reinforced polymer based materials (CRP). In particular, the automotive, aerospace and energy sectors are relevant industrial environments in this respect. The machining of CRP materials is challenging with respect to the obtainable part quality and tool wear. Within the EUREKA project, the WZL cooperates closely with selected partners from ... More...


 

Titanium aluminides are characterised by low density, a high melting point as well as high corrosion resistance, high creep resistance and high tensile strength up to a temperature range of 750°C. These characteristics predestine this material for applications in the turbine and engine technology. The emphasis of the work lies in systematic investigations of the physical mechanisms during cutting of titnium aluminides. The results of the work should help to contribute guidelines ... More...


 

Goal of this research project is to increase productivity and process reliability for drilling of small bore diameters (D ≤ 1 mm) and for thread production of hard-to-cut lead free copper alloys. To realize this objective, the primary machinability problems of selected copper alloys are investigated and analyzed as a first step. In the second step, tool geometries, cutting materials and coatings, machining strategies and parameters as well as cooling lubricant strategies are optimized. The currently missing know-how of an economical way to manufacture parts ... More...


 

95% of the zinc alloys used today are manufactured by pressure die casting where machining is of subordinate importance. As a result of new plant technologies, new wrought zinc alloys have been developed that are produced by extruding as bar material. This results in new applications, especially in the brass industry. The machinability of brass alloys is dramatically increased by alloying with lead. This shall be restricted due to the damaging effect on health and environment of lead. In the future, lead free wrought zinc alloys could provide an ... More...


 

Do you have questions concerning this research area?

Your contact:
Martin Seimann, M.Sc.
Workgroup Leader
Herwart-Opitz-Haus 54B 304
Tel.: +49 241 80-28020
Fax: +49 241 80-22293
Mail: M.Seimann@wzl.rwth-aachen.de

 

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