Functionality-based technology development in wire electrical discharge machining (T01*)

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The overall goal of the new transfer project is the practical, experimental development of a functionality-based technology design for wire electrical discharge machining (WEDM) based on the concept of the process signature. For this, it is necessary that the description of the correlation between external thermal load and material modification is first fully examined, in order to create the conditions for later disclosure of the results for the process signature. The focus of the work is on the development of a generic description of the coupled process energy, with the help of which a defined surface modification is to be set. Subsequently, the resulting functional properties are to be checked on the basis of various dynamic component strength tests for a wire-eroded nickel-based material from turbomachinery engine construction. In particular, the real operating conditions and the manufacturing process chain should also be examined. In this way, a paradigm shift in the previous process design in the industrial environment is to be addressed, so that after the completion of the research project, technologies can be designed with regard to the extended surface integrity and the resulting component functionality. The model description of the correlation between the coupled local discharge energy or power and the resulting functional properties is intended to represent a significant preparatory work for the third funding phase of the SFB. Thus, the prerequisite for a comprehensive validation and a complete industrial implementation of the concept of process signatures should be created after the completion of the SFB. What is scientifically new in this project is the possibility of describing the energy dissipation in three-dimensional, spatially resolved manner and, through the involvement of the machine manufacturer, being able to fully take into account the inaccessible process control parameters in the energetic analysis. Furthermore, the involvement of the end user ensures that, in addition to the wire erosion process, complete manufacturing process chains and the specific conditions of use can be examined when analyzing the functional properties.