Numerical simulation

Combination of simulations and experiments ensures realistic results

Numerical simulations are a very effective means of analyzing relations and tendencies in combination with a minimum of time-consuming experiments. A great advantage lies in investigating areas and processes that can usually hardly be characterized by metrology due to spatial reasons, high mechanical or thermal stresses or due to extremely rapid processes.  Finally, computations by numerical simulation allow for “a look inside” of workpieces or tools. They can even be applied if experimental tests are impeded or impossible because of high cost or safety issues. By utilizing this method, processes can be examined at an early stage of development in order to detect weak points and to find possibilities to improve them.

  • Effectively designing cutting tools by simulation
  • Numerical simulation of chip formation and burr formation
  • Thermal deformations of cutting tools
  • FEM modeling of thin coatings
  • FEM modeling of adaptive clamping elements for thin-walled components
  • FEM modeling of coated forming tools
  • Fundamental technologies and high-performance machining of titanium alloys

  • Analysis of chip formation, chip breaking and burr formation in order to achieve high process reliability and component quality
  • Computation of thermomechanical component deformation for compensating or correcting shape deviations and dimensional tolerances in machining processes
  • Determination of the thermomechanical tool stress for wear reduction
  • Holistic investigation of the static and dynamic system of machine-tool-workpiece

Development of process chains

  • Market 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

Development and evaluation of machining strategies  

  • Market analysis
  • Feasibility studies
  • Technology development
  • Developing process characteristics and optimal machining strategies
  • Numerical simulation
  • Manufacturing of prototypes

Quality assurance

  • Photogrammetrical logging of component and tool geometry
  • Measurement of micro 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
  • CNC lathe N20 with high pressure unit
  • Turning and milling machining center GMX 250 linear
  • ...


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

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
  • More info