Flexible mono- and multilayer micro grinding tools for ultra-high precision processing and micro machining of ductile materials

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The current state of the research shows increasing requirements to the performance and efficiency of high-alloy stainless steel components with high surface quality and functionalized surfaces. The former can be manufactured by ultra-high precision processing, and the letter by means of micro grinding. As part of this project both, the requirements profile of surface grinding (ultra-high precision processing) and peripheral grinding (micro grinding) will be produced by a single novel procedure. However, up until now there is no knowledge of the boundary conditions of the thin film technology for high quality machining of mono- and multilayer micro grinding tools. At the beginning of the project the manufacturing process will be considered to achieve the defined goal. As regards to the demands made on the micro grinding tools the properties are being evaluated. The grinding tools which are developed and manufactured for the use of micro-abrasiv grinding are examined on the following with regard to their behavior in the use of ultra-precision- and micromachining. The next step is a process modeling concerning behaviors of abrasive layer and support layer. In addition, the removal behavior is described in terms of an empirical model. Based on the manufacture of suitable microstructures the established models are finally validated. Furthermore, the process strategy is considered. Thereby solutions for overcoming limitations of the structure geometry are worked out. Finally, a suited tool manufacturing for the transfer of various application scenarios takes place.