Fundamental analysis of surface finishing using flexible foams coated with diamonds

使用涂有金刚石的软质泡沫进行表面精加工的基础分析

• 批准号: 423137098
• 负责人: Professor Dr.-Ing. Dirk Biermann
• 金额: --
• 依托单位: Institut für Spanende Fertigung
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2019
• 资助国家: 德国
• 起止时间: 2018-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/423137098?language=en
• 关键词: Fundamental; analysis; surface; finishing; using

Surfaces with defined functional properties are used in various industrial applications. In production engineering, a reduction of friction and a control of the material flow are often desired functional properties. In this respect, deterministic surface structures on forming tools and chip guiding geometries on cemented carbide tools are typical examples. Due to the production process using geometrically defined cutting tools, filigree and complex form elements, which determine the properties of the surface, are often overlaid by an increased roughness. As a result the potential of the filigree structures cannot be fully realised. In order to reduce roughness, processes with geometrically undefined cutting edges are generally suitable for a post-treatment of the surface. However, the shape of the filigree structures does not have to be affected negatively.Soft foams that are coated with diamonds represent a novel and very flexible tool concept for this application. In addition to a high pore volume, they are characterized by a high softness leading to a promising adaptability especially for complex structures. The aim of this project is to qualify diamond coated foams for the post-treatment of filigree and complex surface structures without affecting their shape. In order to allow a targeted use, there is the need for fundamental, comprehensive academic analysis of the process behaviour, which is the subject of the project described. The analysis of the macroscopic and mesoscopic deformation behaviour of the flexible foams is of high interest, because a homogenous contact situation is of crucial importance for a uniform surface preparation. In this respect, the experiments also focus the influence of the surface pressure and the number of the active diamond grains on the surface topography. Moreover, to use the diamond-coated foams on a machine tool, an analysis of the crucial process parameters on the surface quality is required. This is necessary to define appropriate process parameters in order to achieve an adequate surface quality. Additionally, relevant influences on the surface quality as the interactions of the tool and the surface of the workpiece, the material separation mechanisms and the wear have to be considered as well. With regard to this, the wear forms as well as the wear-induced influences on the created surface topography are analysed. By taking into account all the relevant aspects of the application behaviour described, the targeted use of diamond-coated foams for surface finishing of filigree structures is to be achieved at the end of this project.

具有定义的功能属性的表面在各种工业应用中被使用。在生产工程中，减少摩擦和控制材料流动通常是所需的功能特性。在这方面，成形刀具上的确定性表面结构和硬质合金刀具上的切屑导向几何都是典型的例子。由于生产过程使用几何定义的刀具，决定表面属性的细丝和复杂形状元素通常被增加的粗糙度覆盖。因此，丝状结构的潜力不能完全实现。为了减少粗糙度，具有几何上未定义的切割刃的加工通常适用于表面的后处理。然而，丝状结构的形状不一定会受到负面影响。覆盖有钻石的软质泡沫代表了一种新的、非常灵活的工具概念，适用于这种应用。除了高孔体积外，它们还具有高柔软性的特点，使其具有良好的适应性，特别是对复杂结构。该项目的目的是在不影响其形状的情况下，鉴定用于细丝和复杂表面结构的后处理的金刚石涂层泡沫。为了能够有针对性地使用，需要对过程行为进行基本的、全面的学术分析，这是所述项目的主题。分析柔性泡沫塑料的宏观和介观变形行为是非常有意义的，因为均匀的接触情况对于均匀的表面制备至关重要。在这方面，实验还重点研究了表面压力和活性金刚石颗粒数对表面形貌的影响。此外，为了在机床上使用金刚石涂层泡沫，需要对影响表面质量的关键工艺参数进行分析。这对于确定适当的工艺参数以获得足够的表面质量是必要的。此外，还必须考虑刀具与工件表面的相互作用、材料分离机制和磨损等因素对表面质量的影响。在此基础上，分析了磨损形式以及磨损对表面形貌的影响。通过考虑到所述应用行为的所有相关方面，本项目结束时将有针对性地使用涂有金刚石的泡沫塑料对细丝结构进行表面处理。