Functionality-based technology development in wire electrical discharge machining (T01*)

新转移项目的总体目标是基于过程特征的概念，对基于功能的线切割加工（WEDM）技术设计进行实际的、实验性的开发。为此，有必要首先充分检查外部热负荷与材料改性之间的相关性的描述，以便为以后公开工艺签名的结果创造条件。工作的重点是对耦合过程能量的通用描述的发展，借助它可以确定表面修饰。随后，将根据来自涡轮机械发动机结构的线蚀镍基材料的各种动态部件强度测试来检查所得到的功能特性。特别是，实际操作条件和制造过程链也应该进行检查。通过这种方式，将解决先前工业环境中工艺设计的范式转变，以便在研究项目完成后，可以根据扩展的表面完整性和由此产生的组件功能来设计技术。耦合局部放电能量或功率与产生的功能特性之间的相关性的模型描述旨在为SFB的第三个资助阶段提供重要的准备工作。因此，在完成SFB之后，应该为过程签名概念的全面验证和完整的工业实现创建先决条件。在这个项目中，科学上的创新之处在于能够以三维、空间分解的方式描述能量耗散，并且通过机器制造商的参与，能够在能量分析中充分考虑到难以获得的过程控制参数。此外，终端用户的参与确保了在分析功能特性时，除了线材侵蚀过程外，还可以检查完整的制造工艺链和特定的使用条件。

The overall goal of the new transfer project is the practical, experimental development of a functionality-based technology design for wire electrical discharge machining (WEDM) based on the concept of the process signature. For this, it is necessary that the description of the correlation between external thermal load and material modification is first fully examined, in order to create the conditions for later disclosure of the results for the process signature. The focus of the work is on the development of a generic description of the coupled process energy, with the help of which a defined surface modification is to be set. Subsequently, the resulting functional properties are to be checked on the basis of various dynamic component strength tests for a wire-eroded nickel-based material from turbomachinery engine construction. In particular, the real operating conditions and the manufacturing process chain should also be examined. In this way, a paradigm shift in the previous process design in the industrial environment is to be addressed, so that after the completion of the research project, technologies can be designed with regard to the extended surface integrity and the resulting component functionality. The model description of the correlation between the coupled local discharge energy or power and the resulting functional properties is intended to represent a significant preparatory work for the third funding phase of the SFB. Thus, the prerequisite for a comprehensive validation and a complete industrial implementation of the concept of process signatures should be created after the completion of the SFB. What is scientifically new in this project is the possibility of describing the energy dissipation in three-dimensional, spatially resolved manner and, through the involvement of the machine manufacturer, being able to fully take into account the inaccessible process control parameters in the energetic analysis. Furthermore, the involvement of the end user ensures that, in addition to the wire erosion process, complete manufacturing process chains and the specific conditions of use can be examined when analyzing the functional properties.