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.

具有明确功能特性的表面用于各种工业应用。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引导几何形状是典型的例子。由于生产过程使用几何定义的切削工具，决定表面特性的细丝和复杂的形状元素通常会被增加的粗糙度所覆盖。因此，花丝结构的潜力无法充分发挥。为了降低粗糙度，具有几何形状不明确的切削刃的工艺通常适合于表面的后处理。然而，金丝结构的形状不必受到负面影响。涂有金刚石的软泡沫代表了该应用的一种新颖且非常灵活的工具概念。除了高孔体积之外，它们还具有高柔软性，特别是对于复杂结构具有良好的适应性。该项目的目的是使金刚石涂层泡沫能够在不影响其形状的情况下对金丝和复杂表面结构进行后处理。为了实现有针对性的使用，需要对过程行为进行基础、全面的学术分析，这也是本项目所描述的主题。软质泡沫的宏观和细观变形行为的分析非常有意义，因为均匀的接触情况对于均匀的表面处理至关重要。在这方面，实验还重点关注了表面压力和活性金刚石晶粒数量对表面形貌的影响。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。为了达到足够的表面质量，必须定义适当的工艺参数。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对表面质量的相关影响。就此而言，分析了磨损形式以及磨损引起的对所创建的表面形貌的影响。通过考虑所描述的应用行为的所有相关方面，在该项目结束时将实现使用金刚石涂层泡沫对花丝结构进行表面精加工的目标。