Fundamental analysis of surface finishing using flexible foams coated with diamonds

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，减少摩擦和控制物料流动通常是需要的功能特性。在这方面，成型刀具的确定性表面结构和硬质合金刀具的切屑导向几何是典型的例子。由于生产过程中使用几何定义的切削工具，决定表面性能的细丝和复杂的形状元素经常被增加的粗糙度覆盖。因此，细丝结构的潜力不能完全实现。为了降低粗糙度，具有几何上未定义切削刃的工艺通常适用于表面的后处理。然而，金丝结构的形状并不一定会受到负面影响。在这种应用中，涂有钻石的软泡沫代表了一种新颖而非常灵活的工具概念。除了高孔隙体积外，它们的特点是高柔软性，特别是对复杂结构具有良好的适应性。该项目的目的是在不影响其形状的情况下，将金刚石涂层泡沫用于细丝和复杂表面结构的后处理。为了允许有针对性的使用，需要对过程行为进行基本的，全面的学术分析，这是项目描述的主题。分析柔性泡沫的宏观和细观变形行为引起了人们的高度关注，因为均匀的接触情况对均匀表面的制备至关重要。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。这是必要的，以确定适当的工艺参数，以实现足够的表面质量。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对表面质量的相关影响。在此基础上，分析了磨损形式以及磨损对表面形貌的影响。考虑到所描述的应用行为的所有相关方面，在本项目结束时，将实现使用钻石涂层泡沫进行花丝结构表面精加工的目标。

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.