Basic research on the immersed tumbling process using magneto-rheological fluid for the specific cutting edge preparation of milling tools – RheoTumble

近年来，微型和精密部件的高效生产变得越来越重要。微铣削是微制造的核心部分。由于对部件的几何和尺寸精度的要求，需要特殊的刀具准备来进行可靠的加工。切削刃的准备是此过程中的重要步骤。最常用的工艺包括磁力抛光和浸入式滚磨。然而，这两种方法都具有与工艺相关的缺点。例如，不可能实现局部限定的加工压力plok和材料分离，这显著地限制了制备。这些缺点可以通过两种方法的组合来克服。因此，该研究项目的总体目标是产生和提供的基础知识，浸没翻滚与磨料磁流变液（MRF）的组合应用。因此，在恒定的空间-时间条件下以及通过动态变化的磁场应用待优化的磨料MRF，用于由硬质合金制成的微铣削工具的特定切削刃制备。为了实现总体目标，正在开发和实施一种使用磨料MRF的浸入式翻滚的创新装置。该设备能够在生产环境中研究磨料MRF的流变、磨料和流动特性。为此目的，首先进行了基本的调查，简化的正方形几何形状。基于所获得的知识，耦合有限元，计算流体力学和DEM模型的开发需要解释和优化的实验研究的结果。最后，技术和战略的使用磨料磁流变液在浸没翻滚的微铣削工具在工业环境中的派生。作为研究项目的结果，基本的科学发现是可用的，使一个良好的控制沉浸翻滚过程的基础上磨料MRF的制备硬质合金微型铣刀的切削刃在工业应用。基于集成到机床中，在研究项目实现后，可以显著减少总加工时间tG。

The efficient production of micro and precision components has gained considerably in importance in recent years and decades. Micro milling is a central part of micro manufacturing. Due to the requirements for geometrical and dimensional accuracy of the components, special tool preparation is required for reliable machining. The preparation of the cutting edges is an important step in this process. The most frequently used processes include magnetic finishing and immersed tumbling. However, both methods have process-related disadvantages. For example, it is not possible to realize locally defined machining pressures plok and material separations, which significantly limits the preparation. These disadvantages can be overcome by a combination of both processes. Therefore, the overall objective of the research project is the generation and provision of fundamental knowledge for the combined application of immersed tumbling with abrasive magnetorheological fluids (MRF). Thereby, an abrasive MRF to be optimized is applied under constant spatial-temporal conditions as well as by dynamically changed magnetic fields for the specific cutting edge preparation of micro-milling tools made of cemented carbide. In order to achieve the overall objective, an innovative device for immersed tumbling using abrasive MRF is being developed and implemented. The device enables the investigation of the rheological, abrasive and flow properties of abrasive MRF in a production environment. For this purpose, basic investigations are first carried out on simplified square geometries. Based on the gained knowledge, a coupled FEM-, CFD- and DEM-model is developed required to interpret and optimize the results of the experimental investigation. Finally, technologies and strategies for the use of abrasive MRF in the immersed tumbling of micro-milling tools in an industrial environment are derived. As a result of the research project, fundamental scientific findings are available enabling a well-defined control of the immersed tumbling process based on abrasive MRF for the preparation of cutting edges of cemented carbide micro-milling tools in industrial applications. Based on the integration into machine tools, a significant reduction of the total machining time tG can be achieved after realization of the research project.