Resource efficiency is gaining relevance in every aspect of production. Hence, cutting tools are exposed to high demands regarding productivity and quality. Considering the various grinding operations in tool manufacturing, flute grinding is the most significant process step as it defines the peripheral cutting edge and the rake face. Therefore, it has a substantial influence on the machining behaviour of, for example, milling tools. When it comes to helical flutes, the complex contact conditions between grinding wheel and tool blank during the multiaxial grinding process are particularly difficult to determine. Due to the lack of knowledge about those contact conditions, the grinding wheels typically used for flute grinding cannot wholly meet the actual process requirements. In order to optimise the design of the grinding wheels, a numerical model was developed. Based on that, a simulation tool was implemented to analyse the complex contact conditions during flute grinding depending on the process parameters and tool/workpiece geometry. The influence of different grinding parameters on the effective contact length, the specific material removal rate and the equivalent chip thickness was evaluated by employing the computer-based model. The generated results were then used to develop a new optimised tool concept for a more efficient flute grinding process.
The grinding wheel topography influences the cutting performance and thus the economic efficiency of a grinding process. In contrary to conventional grinding wheels, super abrasive grinding wheels should undergo an additional sharpening process after the initial profiling process to obtain a suitable microstructure of the grinding wheel. Due to the lack of scientific knowledge, the sharpening process is mostly performed manually in industrial practice. A CNC-controlled sharpening process can not only improve the reproducibility of grinding processes but also decrease the secondary processing time and thereby increase the economic efficiency significantly. To optimize the sharpening process, experimental investigations were carried out to identify the significant sharpening parameters influencing the grinding wheel topography. The sharpening block width lSb, the grain size of the sharpening block dkSb and the area-related material removal in sharpening V’’Sb were identified as the most significant parameters. Additional experiments were performed to further quantify the influence of the significant sharpening parameters. Based on that, a process model was developed to predict the required sharpening parameters for certain target topographies. By using the process model, constant work results and improved process reliability can be obtained.
Mit steigenden Anforderungen an Zerspanwerkzeuge hinsichtlich Qualität und Wirtschaftlichkeit gewinnt die Schneidkantenpräparation immer mehr an Bedeutung. Definierte Schneidkantenmikrogeometrien können dabei die Standzeiten der Zerspanwerkzeuge erhöhen. Ein hohes Potenzial für die Herstellung von definierten Schneidkantenmikrogeometrien weist das 3D-Formschleifen auf. Im Rahmen eines Forschungsprojektes wurde die Eignung von 3D-Formschleifen zur Herstellung definierter Schneidkantenmikrogeometrien an keramischen Wendeschneidplatten untersucht.
With increasing demands on cutting tools in terms of quality and economy, cutting-edge preparation becomes more and more important. Defined cutting-edge micro geometries can increase the lifetime of a cutting tool. 3D-form grinding has great potential for the production of defined cutting-edge micro geometries. As part of a research project, the suitability of 3D-form grinding for the production of defined cutting-edge micro geometries on ceramic indexable inserts was examined.
Die stetige Weiterentwicklung von Abrichtwerkzeugen führt zu vermehrt neuartigen Formrollen. Jedoch sind die Wirkzusammenhänge der unterschiedlichen Abrichterspezifikationen auf den Abrichtprozess derzeit unzureichend untersucht worden. Dabei hat der Abrichtprozess einen wesentlichen Einfluss auf das gewünschte Schleifergebnis. In technologischen Untersuchungen soll daher das Einsatzpotenzial von neuartigen Voll-CVD-Formrollen analysiert werden.
The continuous development of dressing tools leads to an increase in new types of dressing rollers. However, the interaction between the various dresser specification and the dressing process has not yet been adequately investigated. The dressing process has a significant influence on the grinding result. It has already been shown that the use of full-CVD-dresser leads to a less tool wear. Therefore, the potential of the new full-CVD-dresser is to be analyzed in technological investigations.
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