On-site processing of complex and cost-intensive capital investments (T09#)

SFB/TR 73的子项目B8主要侧重于评估金属板成形工具的局部、面向载荷的表面和次表面改性和再生的磨削策略，以及开发适合表面区域的CAM规划模块。利用环面刀具磨削B8子项目的结果，建立了残余应力感应的经验亚表面模型。本建议的重点是将这些成果转化为工业应用。这是由Picum MT GmbH， BDW-BINKA Diamantwerkzeug GmbH和汉诺威莱布尼茨大学（LUH）生产工程和机床研究所（IFW）合作完成的。计划项目的重点是将环面刀具磨削的具体次面改造和适应次面的CAM规划知识转移到移动机床上，以实现成形刀具的现场加工。为此，为磨削过程开发的地下模型从SFB/TR 73转移到移动机床的改变边界条件。现有的知识是适应封闭机床外冷却和润滑情况的变化。为此，与合作伙伴BDW-BINKA共同开发了新的刀具概念，可以在没有冷却润滑剂的情况下进行加工，同时满足表面和次表面性能的要求，并具有足够的刀具寿命。此外，在Transregio 73中制定的CAM规划将进一步发展成为综合CAD/CAM模块。为此，在现场测量实际部件的几何形状并将其转换为CAD模型。CAD模型用于识别和定义要加工的区域。通过SFB/TR 73中开发的路径规划，将其传输到移动机器，可以实现所需地下属性的本地设置。在完成转移项目后，可以使用一种基于真实组件几何形状的工艺，该工艺可以实现面向组件的现场加工，并具有特定负载的适应地下。该过程有助于缩短制造和维护过程，从而增加复杂和成本密集型资本货物的盈利能力。

The subproject B8 of the SFB/TR 73 focused mainly on the evaluation of grinding strategies for local, load-oriented surface and subsurface modification and regeneration of sheet metal forming tools as well as the development of a module for CAM planning adapted to the surface zone. The results obtained in the B8 subproject on grinding with toric tools were used to develop an empirical subsurface model for induction of residual stresses. The present proposal focuses on the transfer of these results into industrial application. This is done in cooperation between Picum MT GmbH, BDW-BINKA Diamantwerkzeug GmbH and the Institute for Production Engineering and Machine Tools (IFW) of Leibniz University Hannover (LUH). The focus of the planned project lies in the knowledge transfer of the specific subsurface modification by grinding with toric tools and the CAM planning adapted to the subsurface to a mobile machine tool in order to realize the machining of forming tools on site. For this, the subsurface model developed for the grinding process is transferred from the SFB/TR 73 to the altered boundary conditions of a mobile machine tool. The existing knowledge is adapted to the changed cooling and lubrication situation outside a closed machine tool. For this purpose, new tool concepts are developed together with the cooperation partner BDW-BINKA, which allow machining without cooling lubricant and at the same time meet the requirements for surface and subsurface properties with sufficient tool life. Furthermore, the CAM planning developed in the Transregio 73 will be further developed into an integrated CAD/CAM module. For this purpose, the real component geometry is measured on site and transferred into a CAD model. The CAD model is used to identify and define the areas to be machined. With the path planning developed in the SFB/TR 73, which is transferred to the mobile machine, a local setting of the desired subsurface properties is made possible. After completion of the transfer project, a process is available which, on the basis of real component geometries, enables component-oriented onsite machining with load-specific adapted subsurface. The process helps to shorten manufacturing and maintenance processes and thusincrease the profit-ability of complex and cost-intensive capital goods.