GrindBall - Novel drive and bearing concept for micro grinding tools

制造具有复杂几何形状的小尺寸零件需要有目的地使机床小型化。一种使加工模块适应缩小工作空间的方法是将工具驱动和轴承组合在一个紧凑的模块中。在第一个资助期，电磁轴承和流体驱动被融合到创新的GrindBall模块中，用于微磨小型腔。这一概念允许对小型球面磨具进行无接触支撑、定位和驱动，以实现材料去除。在成功实施加工模块原型的基础上，脆性材料的微细磨削及其新颖的模块内在加工运动学将在第二个资助期进行研究。本研究中产生的磨削结果将首次用于开发无轴磨削工具(无轴磨削)的微细磨削工艺窗口。通过在混合和多相流体驱动、低剩磁和高铁磁性材料领域的进一步研究，以及对磨具定位过程中的电磁效应的研究，将开发提高驱动功率和刀具定位动力学的新方法。此外，应通过力控制磨削、开发和研究选定工艺参数的控制来更有效地利用可用的加工功率。控制途径可以是Grindball模块本身，也可以是优先方案内研究伙伴的供给模块。分析微细研磨过程中Grindball模块与测量模块或进给模块之间的相互作用也是下一个资助期的研究课题。在优先方案的复杂阶段与研究伙伴不断交换信息，以及部署方案本身的共同机械、信息和能量接口，应加强Grindball与小型机床其他模块的特别组合能力。拟议项目的最终目标是通过优先方案1476内计划的调查和合作活动，在小型机床上实现脆性材料的无轴微磨削。

The manufacturing of small scaled parts with complex geometries requires a purposeful miniaturisation of machine tools. One approach for the adaption of machining modules into reduced work spaces is the combination of tool drive and bearing in one compact module. During the first funding period, an electromagnetic bearing and a fluidic drive were fused into the innovative GrindBall module for the purpose of micro grinding small cavities. This concept allows a contact-free support, positioning and drive of a small scaled, spherical grinding tool in order to achieve material removal.Based on the successful implementation of the machining module's prototype, micro grinding of brittle materials and its novel, module inherent machining kinematics shall be investigated in the second funding period. The grinding results generated in this investigation will be used to develop a process window for the micro grinding with a shaft-free grinding tool (axis-free grinding) for the first time. New methods to increase drive power and tool positioning dynamics shall be developed by further research in the fields of hybrid and multi-phase fluidic drives, low remanence and highly ferromagnetic materials as well as investigations of electromagnetic effects during the positioning of the grinding tool. In addition, the available machining power shall be used in a more efficient way by means of force controlled grinding, developing and investigating the control of selected process parameters. The control route may be the GrindBall module itself or feed modules of research partners within the priority programme. The analysis of interactions between the GrindBall module and measurement modules or feed modules during micro grinding is also a research topic in the next funding period. GrindBall's ad hoc combinability with further modules of the small machine tool shall be intensified by a continuously exchange of information with research partners during the complexity phase of the priority programme and the deployment of the programme's own common mechanical, informational and energetic interface. The ultimate goal within the proposed project is to implement axis-free micro grinding of brittle materials in a small machine tool through the planned investigations and cooperation activities within the priority programme 1476.