Fundamental analysis of surface finishing using flexible foams coated with diamonds

具有定义的功能特性的表面用于各种工业应用。在生产工程中，减少摩擦和控制材料流动通常是所需的功能特性。在这方面，成形刀具上的确定性表面结构和硬质合金刀具上的切屑引导几何形状是典型的例子。由于使用几何定义的切削刀具的生产过程，决定表面特性的细丝和复杂形状元素通常被增加的粗糙度覆盖。因此，细丝结构的潜力不能完全实现。为了降低粗糙度，具有几何上未定义的切削刃的工艺通常适合于表面的后处理。然而，这些细丝结构的形状不会受到负面影响。涂覆金刚石的软泡沫代表了该应用的一种新颖且非常灵活的工具概念。除了高孔隙体积之外，它们的特征在于高柔软性，这导致特别是对于复杂结构的有希望的适应性。该项目的目的是使金刚石涂层泡沫有资格用于金银丝和复杂表面结构的后处理，而不影响其形状。为了允许有针对性的使用，有必要对过程行为进行基本的，全面的学术分析，这是所描述的项目的主题。软质泡沫的宏观和介观变形行为的分析是高度感兴趣的，因为均匀的接触情况是至关重要的均匀的表面制备。在这方面，实验也集中在表面压力和活性金刚石颗粒的数量对表面形貌的影响。此外，为了在机床上使用金刚石涂层泡沫，需要分析影响表面质量的关键工艺参数。这对于确定适当的工艺参数以实现足够的表面质量是必要的。此外，还必须考虑刀具与工件表面的相互作用、材料分离机制和磨损对表面质量的相关影响。关于这一点，磨损的形式以及磨损引起的影响上创建的表面形貌进行了分析。通过考虑所描述的应用行为的所有相关方面，在该项目结束时，将实现金刚石涂层泡沫用于金银丝结构表面精加工的目标。

Surfaces with defined functional properties are used in various industrial applications. In production engineering, a reduction of friction and a control of the material flow are often desired functional properties. In this respect, deterministic surface structures on forming tools and chip guiding geometries on cemented carbide tools are typical examples. Due to the production process using geometrically defined cutting tools, filigree and complex form elements, which determine the properties of the surface, are often overlaid by an increased roughness. As a result the potential of the filigree structures cannot be fully realised. In order to reduce roughness, processes with geometrically undefined cutting edges are generally suitable for a post-treatment of the surface. However, the shape of the filigree structures does not have to be affected negatively.Soft foams that are coated with diamonds represent a novel and very flexible tool concept for this application. In addition to a high pore volume, they are characterized by a high softness leading to a promising adaptability especially for complex structures. The aim of this project is to qualify diamond coated foams for the post-treatment of filigree and complex surface structures without affecting their shape. In order to allow a targeted use, there is the need for fundamental, comprehensive academic analysis of the process behaviour, which is the subject of the project described. The analysis of the macroscopic and mesoscopic deformation behaviour of the flexible foams is of high interest, because a homogenous contact situation is of crucial importance for a uniform surface preparation. In this respect, the experiments also focus the influence of the surface pressure and the number of the active diamond grains on the surface topography. Moreover, to use the diamond-coated foams on a machine tool, an analysis of the crucial process parameters on the surface quality is required. This is necessary to define appropriate process parameters in order to achieve an adequate surface quality. Additionally, relevant influences on the surface quality as the interactions of the tool and the surface of the workpiece, the material separation mechanisms and the wear have to be considered as well. With regard to this, the wear forms as well as the wear-induced influences on the created surface topography are analysed. By taking into account all the relevant aspects of the application behaviour described, the targeted use of diamond-coated foams for surface finishing of filigree structures is to be achieved at the end of this project.