TR73

  • Increase font size
  • Default font size
  • Decrease font size


B3 - Surface Structures (funding period 2)



Generation of Predetermined Surface Structures by Simulation based Process and Tool Design when Milling Free-Formed Surfaces

Project Status: finished

Last Update: 23.01.2017



Members


The subject of this project is to generate predefined surface textures when milling free-formed surfaces of the forming dies. The machined surfaces are supposed to be functional surfaces of the forming tool. Therefore they have to be milled in tempered tool steel. In the first phase of the project the connection between process parameters and produced structures was explored. Based on the results the focus in the current phase are the needs when machining real forming tools.

Simulation comparison


Figure 1: Comparison of measured and simulated structures which were produced by high-feed milling.

The used structuring methods are milling with intentionally invoked tool vibrations (chatter vibrations) and milling with high feed tools. The generated structures either decrease or increase the friction during forming. The tribological properties of the structures are quantified by an adapted ring crush test.

Figure 2: Tools for structuring by milling and structured workpiece.

Apart from generating structures with the mentioned processes, another subject is to structure forming tools with Precise Electrochemical Machining (PEM). With this method, no residual stresses are applied to the forming tool which has a positive influence on the durability.

PEM Process english

Figure 3: a) PEM Process, b) Schematic setting of PEM-tool, c) accurate reproduction of surface detail and tribological investigations


Working Groups


Publications

    2016

    • Löffler, M.; , .; Engel, U.; Schulte, R.; Gröbel, D.; Krebs, E.; Freiburg, D.; Biermann, D.; Stangier, D.; Tillmann, W.; Weikert, T.; Wartzack, S.; Tremmel, S.; Lucas, H.; Denkena, B.; Merklein, M.: Tribological measures for controlling material flow in sheet-bulk metal forming. In: Production Engineering, (2016), accepted
    • Kersting, P.; Gröbel, D.; Merklein, M.; Sieczkarek, P.; Wernicke, S.; Tekkaya, A.; Krebs, E.; Freiburg, D.; Biermann, D.; Weikert, T.; Tremmel, S.; Stangier, D.; Tillmann, W.; Matthias, S.; Reithmeier, E.; Löffler, M.; Beyer, F.; Willner, K.: Experimental and numcerial analysis of tribological effective surfaces for forming tools in Sheet-Bulk Metal Forming. In: Production Engineering, 10(2016)1, Springer, pp. 37-50
    • Tillmann, W.; Stangier, D.; Laemmerhirt, I.-A.; Biermann, D.; Freiburg, D.: Investigation of the tribological properties of high-feed milled structures and Cr-based hard PVD-coatings. In: Vacuum, 131(2016), pp. 5-13

    2015

    • Freiburg, D.; Biermann, D.; Hense, R.; Tillmann, W.; Stangier, D.: Influence of Surface Modifications on Friction, Using High-Feed Milling and Wear Resistant PVD-Coating for Sheet-Metal Forming Tools. In: Key Engineering Materials, 639(2015), pp. 275-282
    • Hense, R.; Kersting, P.; Vierzigmann, U.; Löffler, M.; Biermann, D.; Merklein, M.; Wels, C.: High-Feed Milling of Tailored Surfaces for Sheet-Bulk Metal Forming Tools. In: Production Engineering, 9(2015)2, pp. 215-223
    • Löffler, M.; Freiburg, D.; Gröbel, D.; Loderer, A.; Matthias, S.; Stangier, D.; Weikert, T.: Untersuchung von Tailored Surfaces hinsichtlich ihres tribologischen Einflusses auf Prozesse der Blechmassivumformung. In: Tekkaya, A. E.; Liewald, M.; Merklein, M.; Behrens, B.-A (Edt.): Tagungsband zum 18. Workshop Simulation in der Umformtechnik & 3. Industriekolloquium Blechmassivumformung 2015 - DFG Transregio 73, (2015), Aachen: Shaker Verlag, pp. 131-146
    • Freiburg, D.; Kersting, P.; Biermann, D.: Simulation and Structuring of Complex Surface Areas using High Feed Milling. In: 8th Iinternatinal Conference and Exhibition on Design and Production of Machines and Dies/Molds, 8(2015), Kusadasi, Aydin, TURKEY, pp. 93-98
    • Lucas, H.; Denkena, B.; Grove, T.; Krebs, E.; Kersting, P.; Freiburg, D.; Biermann, D.: Analysis of Residual Stress States of Structured Surfaces Manufactured by High-Feed and Micromilling. In: HTM Journal of Heat Treatment and Materials, 70(2015)4, pp. 183-189
    • Freiburg, D.; Hense, R.; Biermann, D.; Kersting, P.: Determination of Force Parameters for Milling Simulations by Combining Optimization and Simulation Techniques. In: J. Manuf. Sci. Eng., 138(2015)4, pp. 6

    2013

    • Hense, R.: Using Chatter Vibrations in Milling to Create Tribo-Functional Surfaces for Sheet-Bulk Metal Forming Tools. In: Advanced Materials Research, 769(2013), pp. 263-270
    • Vierzigmann, U.; Schneider, T.; Koch, J.; Merklein, M.; Engel, U.; Hense, R.; Biermann, D.; Krebs, E.; Kersting, P.; Lucas, H.; Denkena, B.; Herper, J.; Tillmann, W.; Stangier, D.: Untersuchungen von Tailored Surfaces für die Blechmassivumformung mittels angepasstem Ringstauchversuch. In: Merklein, M.; Behrens, B. A., Tekkaya, A. E. (Edt.): 2. Workshop Blechmassivumformung, (2013), Bamberg: Meisenbach, pp. 137-162
    • Breitsprecher, T.; Hense, R.; Beyer, F.; Biermann, D.; Wartzack, S.; Willner, K.: Sensitivitätsanalyse der tribologischen Eigenschaften gefräster Oberflächenstrukturen bei der Blechmassivumformung. In: Merklein, M.; Behrens, B. A., Tekkaya, A. E. (Edt.): 2. Workshop Blechmassivumformung, (2013), Bamberg: Meisenbach, pp. 121-136

    Presentations

      2016

      • 17.04.2016: Freiburg, D.: Oberflächenstrukturen in der Spanenden Fertigung, DGM Seminar, Dortmund

      2015

      • 17.03.2015: Biermann, D.; Freiburg, D.; Hense, R.; Tillmann, W.; Stangier, D.: Influence of surface modifications on friction, using high-feed milling and wear resistant PVD-coating for sheet-metal forming tools, Erlangen, Germany
      • 19.06.2015: Freiburg, D.: Simulation and Structuring of Complex Surface Areas using High Feed Milling, Kusdsadasi, Aydin, Turkey

      2013

      • 24.07.2013: Hense, R.: Erzeugung tribologisch wirksamer Oberflächen für Umformwerkzeuge der Blechmassivumformung durch regenerative Werkzeugschwingungen beim Fräsen, Erlangen
      • 13.11.2013: Koch, J.: Untersuchung von Tailored Surfaces für die Blechmassivumformung mittels angepasstem Ringstauchversuch, Erlangen
      • 13.11.2013: Breitsprecher, T.: Vortrag bearbeiten: Sensitivitätsanalyse der tribologischen Eigenschaften gefräster Oberflächenstrukturen bei der Blechmassivumformung, Erlangen