On-site processing of complex and cost-intensive capital investments (T09#)

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The subproject B8 of the SFB/TR 73 focused mainly on the evaluation of grinding strategies for local, load-oriented surface and subsurface modification and regeneration of sheet metal forming tools as well as the development of a module for CAM planning adapted to the surface zone. The results obtained in the B8 subproject on grinding with toric tools were used to develop an empirical subsurface model for induction of residual stresses. The present proposal focuses on the transfer of these results into industrial application. This is done in cooperation between Picum MT GmbH, BDW-BINKA Diamantwerkzeug GmbH and the Institute for Production Engineering and Machine Tools (IFW) of Leibniz University Hannover (LUH). The focus of the planned project lies in the knowledge transfer of the specific subsurface modification by grinding with toric tools and the CAM planning adapted to the subsurface to a mobile machine tool in order to realize the machining of forming tools on site. For this, the subsurface model developed for the grinding process is transferred from the SFB/TR 73 to the altered boundary conditions of a mobile machine tool. The existing knowledge is adapted to the changed cooling and lubrication situation outside a closed machine tool. For this purpose, new tool concepts are developed together with the cooperation partner BDW-BINKA, which allow machining without cooling lubricant and at the same time meet the requirements for surface and subsurface properties with sufficient tool life. Furthermore, the CAM planning developed in the Transregio 73 will be further developed into an integrated CAD/CAM module. For this purpose, the real component geometry is measured on site and transferred into a CAD model. The CAD model is used to identify and define the areas to be machined. With the path planning developed in the SFB/TR 73, which is transferred to the mobile machine, a local setting of the desired subsurface properties is made possible. After completion of the transfer project, a process is available which, on the basis of real component geometries, enables component-oriented onsite machining with load-specific adapted subsurface. The process helps to shorten manufacturing and maintenance processes and thusincrease the profit-ability of complex and cost-intensive capital goods.