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

新转移项目的总体目标是基于工艺特征概念的基于功能的电火花线切割加工（WEDM）技术设计的实践和实验开发。为此，必须首先全面检查外部热负荷和材料改性之间的相关性的描述，以便为稍后公开工艺特征的结果创造条件。工作的重点是对耦合过程能量的一般描述的发展，与此帮助下，一个定义的表面改性是要设置。随后，将根据各种动态部件强度试验，对涡轮发动机结构的线腐蚀镍基材料进行功能特性检查。特别是，还应检查真实的操作条件和制造工艺链。通过这种方式，将解决工业环境中先前工艺设计的范式转变，以便在研究项目完成后，可以设计关于扩展表面完整性和由此产生的组件功能的技术。耦合的局部放电能量或功率和由此产生的功能特性之间的相关性的模型描述旨在代表SFB的第三资助阶段的重要准备工作。因此，一个全面的验证和一个完整的工业实施的过程签名的概念的先决条件，应创建完成后的SFB。在这个项目中，科学上的新技术是以三维空间分辨的方式描述能量耗散的可能性，并且通过机器制造商的参与，能够在能量分析中充分考虑无法访问的过程控制参数。此外，最终用户的参与确保了在分析功能特性时，除了电线腐蚀过程之外，还可以检查完整的制造工艺链和特定的使用条件。

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.