Fraunhofer Institute for Machine Tools and Forming Technology
Fraunhofer Institute for Machine Tools and Forming Technology

Removal

From macro to micro ranges – removal in efficient process chains

Functional design of surfaces and manufacturing of more and more miniaturized systems demands excellent process knowledge and constant adaptation to current requirements. Removal processes offer great potential, in particular electrochemical machining (ECM), electrical discharge machining (EDM) and laser beam machining (LBM), especially in combination with process chains using cutting technology. In addition to optimizing these manufacturing technologies, our focus lies on designing components, processes and process chains and on application-oriented development of measuring systems and evaluation systems.

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  • Resource-efficient process chains for difficult-to-machine materials with macro and micro geometries
  • Process control by parameterization and simulation
  • Optimization of processes and machines
  • Hybrid processes and process combinations
  • Integration of actuator systems for process stabilization, increase of removal and precision

Analysis, modeling and simulation

  • Analysis of the removal technologies ECM, EDM, LBM as well as associated machining tasks and process chains
  • Modeling of the removal behavior
  • Process simulation to facilitate tool design
  • Design and optimization of manufacturing processes for technologies in series production
  • Planning and technological dimensioning of processes, tools and machines (cost-benefit calculations)

Development and evaluation

  • Development of manufacturing technologies for producing functional surfaces (tribologically optimized surfaces, sealing surfaces and joining areas, surfaces with biological functions)
  • Continuous development of technologies and process chains for manufacturing microstructures and functional surfaces
  • Optimizing the generator technology for ECM and EDM
  • Development, design, construction and commissioning of equipment for serial applications
  • Developing components for optimizing machines / evaluating components
  • Feasibility studies and manufacturing of prototypes (for example for processing difficult-to-machine materials such as PM steels, high-strength non-ferrous metals, carbide materials, ceramics, etc.)

Quality assurance

  • Metrology applied to determine characteristics of components and surfaces
  • Measuring systems and evaluation systems for evaluating functions
  • Feedback on modeling and simulation

Machine technology

  • High-precision 3-axis micro EC machining facility
  • PEM Center 8000 (PECM) with x-y table
  • Prototype plant Jet-ECM
  • Device for material removal analysis
  • System for micro electrical discharge machining Sarix T1-T4
  • Laser microstructuring machine ACSYS ORCAµ
  • Laser microstructuring machine JenLas epidot 4
  • Multi-axis laser center ACSYS ORCAµ with 2 integrated laser sources
  • 5-axis micro machining center Kugler MM3

Software

  • FEM simulation software COMSOL Multiphysics™
  • Software for surface imaging and analysis MountainsMap6.2®
  • Various CAD/CAM software
  • Supercomputer with 32 CPU cores and 512 GB RAM
  • Supercomputer with 16 CPU cores and 196 GB RAMnsMap6.2®
  • Commercial software COMSOL Multiphysics 5.1

Testing technology

  • 3D coordinate measuring instrument Zeiss Prismo
  • Confocal microscope, measuring microscope
  • White light interferometer, fringe projection system MikroCAD
  • Scanning electron microscope REM VP 1455 with EDX system
  • Rotational tribometers WAZAU TRM 500 and TRM 5000
  • Translational tribometer ”Optimol SRV5“
  • Laser interferometer Renishaw
  • Various devices for measuring roughness and profiles
  • Micro balances
  • Compact mass spectrometer QMS 220
  • Measuring system for forms and positions MMQ 200