FOR 1845: Ultra-Precision High Performance Cutting (UP-HPC)

研究单位的目标是通过科学手段减少超精密加工中过多的一次和二次加工时间，以利用该技术在制造业中的经济适用性。第一个项目侧重于使用多种刀具进行超精密加工。由于对精度的要求，这种方法在目前的技术下是不可行的。因此，该项目采用了一种新颖的方法，该方法基于刀架的受控热膨胀来对齐单个切削刃。第二个项目的重点是通过分析高速切削对金刚石刀具磨损和加工工件表面完整性的影响，对高速切削在金刚石铣削中的应用进行科学评价。在第三个项目中，将开发一种电磁驱动的超精密直线导轨，它将实现快速和无摩擦的精确运动。利用这种方法，可以实现超精密加工过程中静态和动态偏差的补偿。由于产生的高离心力，高速主轴需要一个非常好的平衡设置。这一专题将在研究股的第四个项目中讨论。将开发一种气轴承主轴精密平衡自动系统，它将完全取代人工平衡，从而大大减少安装时间。然而，这种方法的科学挑战在于能够测量和补偿极小的残余不平衡，这些残余不平衡低于传统传感器系统的检测阈值。第五个项目旨在为超精密机床的动态行为的过程中分析奠定基础，以确保在开始实际切割操作之前以及在切割工件期间加工过程的可靠性。因此，将建立机床结构和切削操作的参数化模型，并在加工实验中进行验证。

The goal of the Research Unit is it to reduce the excessive primary and secondary processing times in ultra-precision machining via scientific means, in order to leverage the economic applicability of this technology in the manufacturing industry. The first project focusses on ultra-precision machining using multiple cutting tools. Due to the required precision, this approach is not feasible with current technology. Thus, this project follows a novel approach based on a controlled thermal expansion of the tool holder to align the individual cutting edges. The focus of the second project is the scientific evaluation of high-speed-cutting (HSC) in diamond milling, by analysing its effect on the wear of the diamond tools as well as on the surface integrity of the machined workpiece. In the third project, an electromagnetically driven ultra-precise linear guide will be developed, which would allow fast and frictionless precision motion. With this means, an in-process compensation of static and dynamic deviations in ultra-precision machining could be achieved. Due to the high resulting centrifugal forces, high-speed spindles require an extremely well balanced setup. This topic will be addressed in the fourth project of the Research Unit. An automatic system for precision balancing of air bearing spindles will developed, which would supersede manual balancing completely and thus reduce setup times considerably. The scientific challenge in this approach, however, is to be able to measure and compensate extremely small residual unbalances, which are below the detection threshold of conventional sensor systems. The fifth project is aimed to lay the foundations for an in-process-analysis of the dynamic behaviour of ultra-precision machined tools, in order to ensure the reliability of the machining process before commencing the actual cutting operation as well as during the cutting of the workpiece. Therefore, a parametric model of the machines structure and the cutting operation will be developed and tested in machining experiments.