Dry machining is one of the most significant developments in manufacturing technology. One main problem in comparison to machining with coolants is that dry machining creates much stronger heating in the workpiece, resulting in shape and dimensional deviations. It is not possible until now, originating from blank contour, depending on processes sequences and cutting conditions, to continuously calculate the expected shape and dimensional deviaitons in dry machining. Regarding to previous studies the heat source and the heat partition were mostly estimated by experiments. The objective of the research project is development of a numerical multiscale model to calculate the thermo-elastic ... More...


 

To a better understanding of relevant properties to increase the lifetime and the performance of mechanical components, an entire gear process chain is studied where the results and considerations are carried interconnecting process-by-process in individual multi-scale simulations. Specifically in WZL Cutting Technology Department, a turning process required in this manufacturing chain is studied focusing on the residual stress influence in consecutive cuts. Orthogonal cutting experiments are conducted with observation of the machining forces, temperatures and chip formation phenomena. With simulation support, the experimental conditions are verified and extrapolated in the direction of designing the residual stress in turning with the cumulative effect of rough and finish cuts. More...


 

The mechanics of the cutting process on the microscopic level differ fundamentally from the conventional macro cutting. For example, the tool edge radius influences the cutting mechanism in micro machining significantly with regard to the effective rake angle, the minimum chip thickness, the dominance of ploughing, and the related elasto-plastic deformation of the workpiece material. These phenomena, known as size effects, have a profound impact on the cutting forces, process stability, and resulting surface finish in micro cutting. Therefore, the simulation of microstructural effects from micro cutting requires new modeling approaches and quite different assumptions concerning the thermo-mechanical material behavior. Against this background, a 3D multiphase FE computational model is developed at WZL within the framework of the DFG project “3D Finite Element Micro ... More...


 

Production sectors like automotive, energy, healthcare and aerospace are faced strong competitive constraints from North America and Asia. To keep the European countries competitive and to create more and better jobs in Europe, investigations in new research areas and innovation is essential. Integrated Computational Materials Engineering (ICME) is one of most attractive emerging discipline for research and innovation because it can accelerate materials development, unify design and manufacturing, help to create new technology area, and hence provide significant economic benefit. Furthermore, ICME is very efficient tool to solve many problems in natural and ... More...


 

Tool wear influences the results of a metal cutting process in various ways. Tool wear affects the cutting force, the achievable surface quality and surface integrity as well as the precision. Futhermore, tool wear affects the economics of the cutting process, since paramteres are always chosen in a trade-off between productivity and tool wear. The project Anwendung der Verschleißsimulation in der Werkzeugentwicklung aims at developing numercial modelling methods to predict tool wear in turning processes under industrially relevant conditions (Coatings, complex micro and macro geometries) in order to support tool and process design. More...


 

Do you have questions concerning this research area?

Your contact:
Markus Meurer, M.Sc. RWTH
Workgroup Leader
Cluster Produktionstechnik 3A 254
Tel.: +49 241 80-28040
Fax: +49 241 80-22293
Mail: M.Meurer@wzl.rwth-aachen.de

 

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