Simulation-based tool design for hand-guided dental grinding processes with electroplated diamond tools

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This research project is a knowledge transfer based on the research project "Modellierung und Simulation des NC-Formschleifens zur gezielten Erzeugung von Werkstückoberflächen unter Berücksichtigung der Werkzeugtopographie und des Werkzeugverschleißes". Based on the results obtained so far, a previously developed geometric physically-based process simulation for NC grinding processes with electroplated diamond tools will be extended in order to design dental instruments which are used in hand-guided machining operations. In this transfer project, the knowledge gained so far will be transferred prototypically to new tool concepts. The research will be carried out in cooperation between the Chair XIV - Virtual Machining at TU Dortmund University and the Gebr. Brasseler GmbH & Co. KG. The central objective of the project is the further development of the simulation system for the design of dental grinding tools and the optimization of hand-guided processes. For validation, prototypical grinding tools will be designed, manufactured and analyzed. Based on the previous findings and the simulation model developed in the previous research project, the transfer to an industrial application will be achieved by specifically designing and optimizing dental instruments. The dental application is a hand-guided and therefore force-controlled process, requiring extensive investigations and significant extensions of the simulation system in this transfer project. By developing a mobile analogy test unit, the tool movements and process forces occurring during hand-guided machining will first be analyzed experimentally. In an analogy test setup, which will be developed in this project, the application behavior of the tools will then be analyzed, especially with regard to tool wear. The knowledge gained will serve as a basis for the further development of the process simulation. The focus is on the development and testing of a corresponding design methodology for optimizing the efficiency and service life of dental grinding tools by designing appropriate tool topographies and process configurations in cooperation with the application partner.