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

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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.