FOR 1845: Ultra-Precision High Performance Cutting (UP-HPC)

FOR 1845：超精密高性能切割 (UP-HPC)

• 批准号: 211652309
• 金额: --
• 依托单位: Fachgebiet Fertigungsverfahren
• 依托单位国家: 德国
• 项目类别: Research Units
• 财政年份: 2014
• 资助国家: 德国
• 起止时间: 2013-12-31 至 2020-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/211652309?language=en
• 关键词: 1845; Ultra; Precision; Performance; Cutting

The goal of the Research Unit is it to reduce the excessive primary and secondary processing times in ultra-precision machining via scientific means, in order to leverage the economic applicability of this technology in the manufacturing industry. The first project focusses on ultra-precision machining using multiple cutting tools. Due to the required precision, this approach is not feasible with current technology. Thus, this project follows a novel approach based on a controlled thermal expansion of the tool holder to align the individual cutting edges. The focus of the second project is the scientific evaluation of high-speed-cutting (HSC) in diamond milling, by analysing its effect on the wear of the diamond tools as well as on the surface integrity of the machined workpiece. In the third project, an electromagnetically driven ultra-precise linear guide will be developed, which would allow fast and frictionless precision motion. With this means, an in-process compensation of static and dynamic deviations in ultra-precision machining could be achieved. Due to the high resulting centrifugal forces, high-speed spindles require an extremely well balanced setup. This topic will be addressed in the fourth project of the Research Unit. An automatic system for precision balancing of air bearing spindles will developed, which would supersede manual balancing completely and thus reduce setup times considerably. The scientific challenge in this approach, however, is to be able to measure and compensate extremely small residual unbalances, which are below the detection threshold of conventional sensor systems. The fifth project is aimed to lay the foundations for an in-process-analysis of the dynamic behaviour of ultra-precision machined tools, in order to ensure the reliability of the machining process before commencing the actual cutting operation as well as during the cutting of the workpiece. Therefore, a parametric model of the machines structure and the cutting operation will be developed and tested in machining experiments.

研究单位的目标是通过科学手段减少超精密加工中过多的初级和次级加工时间，以利用该技术在制造业中的经济适用性。第一个项目专注于使用多个刀具的超精密加工。由于所需的精度，这种方法在当前技术下是不可行的。因此，该项目遵循一种基于工具保持器的受控热膨胀的新方法，以对齐各个切削刃。第二个项目的重点是科学评估金刚石铣削中的高速切削（HSC），分析其对金刚石工具磨损以及加工工件表面完整性的影响。在第三个项目中，将开发电磁驱动的超精密线性导轨，这将允许快速和无摩擦的精密运动。该方法可实现超精密加工中静、动态误差的在线补偿。由于产生的高离心力，高速主轴需要非常平衡的设置。研究股的第四个项目将讨论这一专题。本文介绍了一种空气轴承主轴精密平衡自动化系统，该系统完全取代了手工平衡，从而大大缩短了调整时间。然而，这种方法的科学挑战是能够测量和补偿非常小的残余不平衡，这低于传统传感器系统的检测阈值。第五个项目旨在为超精密加工刀具的动态行为的过程分析奠定基础，以确保在开始实际切削操作之前以及在工件切削期间加工过程的可靠性。因此，将开发机器结构和切削操作的参数化模型，并在加工实验中进行测试。