Cutting

High-performance components and tools for cutting

© Jürgen Jeibmann / Fraunhofer IWU

Our research activities focus on developing and optimizing innovative cutting technologies, on shortening process chains, particularly for tool and die making, for powertrain components and parts for the aerospace industry, power engineering and medical engineering.

Fields of activity

  • Numerical simulation of cutting processes, machining tools and component behavior
  • Development of cutting processes
  • Design of process chains, combination and integration of processes
  • Development of hybrid machining processes by using active media and superimposed movements due to vibrations, heat or cold and pressure (coolants)
  • Development and testing of intelligent adaptronic tools by using sensor-actuator systems
  • Analysis of NC data chaining and development of CAM machining strategies
  • Design, manufacturing and evaluation of tribologically optimal functional surfaces
  • Dimensioning, development and construction of machine tools and assembly groups

  • Hybrid machining
  • Dry machining
  • 5-axis simultaneous machining
  • Hard machining
  • Preventive non-circular machining

Development of process chainsMarket analysis

  • Investigation of process chains
  • Process optimization
  • Cost-benefit calculation
  • Development of manufacturing concepts
  • Rough and detailed planning of technological processes
  • Technological dimensioning of cutting machines
  • Preparation of specifications and machine concepts
  • Recommendations for machine investments
  • Design planning
  • Optimization of process control

Development and evaluation of machining strategies
Market analysis

  • Feasibility studies
  • Technology development
  • Developing process characteristics and optimal machining strategies
  • Benchmarking of CAD/CAM systems
  • Numerical simulation
  • Manufacturing of prototypes

Quality assurance

  • Photogrammetrical logging of component and tool geometry
  • Measurement of components using confocal microscopy and fringe projection
  • Measuring of machines and tools
  • Structural analysis using scanning electron microscope

Machine technology

  • 5-axis machining center DMU210P

  • 5-axis Hexapod milling machine Mikromat 6X HEXA
  • 5-axis multifunction machine Dynapod
  • 5-axis milling machine DIGMA 850 HSC
  • 5-axis micro machining center KUGLER
  • 5-axis horizontal machining center HEC 630
  • 4-axis horizontal machining center HEC 500D XXL
  • 3-axis vertical machining center CSK400
  • CNC lathe N20 with high pressure unit

Software

  • CAD systems: Inventor, Pro-Engineer, CATIA
  • CAM systems: Tebis, GIB CAD&CAM, Technomatics MLP, software for non-circular grinding KEL-POLY, graphical programing software KEL-ASSIST
  • Finite element software: ABAQUS, MARC, ANSYS, DEFORM
  • Simulation software: RealNC, NCSpeed

Testing technology

  • Precision measuring machine PRISMO7S-ACC (ZEISS)
  • Various devices for measuring optical roughness and profiles
  • Confocal microscope, ITO Stuttgart University
  • White light interferometer, ITO Stuttgart University
  • MikroCAD, GFM Teltow
  • Vcheck, GFM Teltow
  • Scanning electron microscope, LEO Oberkochen
  • EDX system, Oxford Instruments
  • Optical measuring station UBM
  • Contact measuring devices for roughness and profiles, HOMMEL and Mitutoyo