Aluminium alloys have found increasing applications in the automotive and aeronautical industries in recent years. Due to their extraordinary properties however, the machining of these alloys still poses difficulties, and requires the optimized combination of cutting tool material and geometry. The potential of CVD diamond coated carbide tools has been demonstrated in recent years, however tool wear and short tool life remain as issues to be resolved. Key to increasing the tool life of CVD diamond coated tools is the further development of the coating process to optimize the coating adhesion. An understanding of the substrate and coating residual stress profiles must be gained in order to achieve this. Compressive residual stresses in cutting tools can lead to a higher crack resistance, but also to early coating delamination and tool failure. To analyze the influence of residual stresses on the coating quality and tool life, the residual stress profiles of tungsten carbide substrates and CVD diamond coatings were measured using X-ray and synchrotron radiation. The influence of the tungsten carbide substrate type and the CVD diamond coating process on the residual stress profiles was thus determined. In order to analyze the performance of the coated tools and the influence of the residual stresses on the tool lifetime, machining tests were performed with two aluminium silicon alloys. The tool wear, tool lifetime and workpiece quality were examined.Finally, many of the commonly used wear tests used to analyze the wear resistance of tool coatings cannot be implemented for CVD diamond coatings due to their high hardness. An impact test was therefore constructed to allow the determination of the wear resistance of CVD diamond tools.
The general approaches to the analysis of rotor steels for antimony, arsenic, tin, lead, bismuth, selenium, tellurium, aluminum, and copper at the 15 ppm level are evaluated. Chemical methods are in existence but are slow. Polarography, with some further development, would also provide usable techniques which would be slow. The instrumental methods optical emission, X-ray fluorescence and atomic absorption do not yield adequate results upon direct application to the specimen. However, with suitable concentration techniques, these methods show considerable promise for rapid analysis of rotor steels. A number of concentration techniques are discussed. Of these, acid precipitation of the sulfides appears to be the best approach. Spark source mass spectrometry, while quite sensitive, is not yet developed to the point of supplying rapid, precise, and accurate quantitative analyses.
In order to provide solutions to the current challenges and discussions on resource efficiency and energy savings, the manufacturing industry must present saving methods, in particular in energy intensive applications. The grinding technologies, with their high demands on precision and integrity of the boundary layer of components are one such application area which must source new and innovative solutions. Due to the ever increasing complexity of components, such as cooling lubricant systems and arrangements for maintaining temperatures of axes and guideways, the demand on machine tools to reach these high accuracies is constantly rising. In order to make a significant contribution to resource efficiency and energy savings, along with research on tool and process optimisation and innovative machining kinematics, the activities of the IWF focus on the substitution of complex machine tools with robot assisted machining strategies in order to simultaneously achieve high flexibility and productivity.
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