Project Details

Professor Dr.-Ing. Thomas Bergs

Address Rheinisch-Westfälische Technische Hochschule Aachen
Manufacturing Technology Institute (MTI)
Campus-Boulevard 30
52074 Aachen

Projects

As Applicant
- Current projects
  - Model predictive force control for multi-axis rough milling (Research Grants)
  - Identification of the mechanisms of action of the tribological behaviour of structured semi-finished product surfaces during full forward extrusion of aluminum alloys with regard to friction and wear reduction (TriboLub) (Research Grants)
  - Analysis of wear mechanisms in grinding of polycrystalline diamond with vitrified bonded grinding wheels based on a friction model (Research Grants)
  - Development and validation of a generic temperature model for milling tools (Research Grants)
  - Experimental and model-based analysis of machining-induced residual stresses and part distortion when turning Inconel 718 (Research Grants)
  - Fundamental study of the electrical and acoustic characterization of different types of single discharges in wire electrical discharge machining (WEDM) (Research Grants)
  - Development of Binder Jetting for highly stressed drive components by sintering according to requirements (Research Grants)
  - Development and investigation of an indirect dynamic force measurement system based on voltage and current signals for cutting technology (Research Grants)
  - hodology for the adaptive design of economically optimized process sequences in the case of short-term disruptions in the manufacturing process (Research Grants)
  - Load and function-oriented tool design for finish turning of rotationally symmetrical components made out of the nickel-based alloy Inconel 718 (Research Grants)
  - Mold materials with adjustable coefficient of thermal expansion for precision glass molding (Research Grants)
  - Performance optimization of spur gears by machine hammered tooth surfaces (OptiGear2) (Research Grants)
  - Investigation of the formation mechanisms of micro lead during external cylindrical plunge grinding of sealing counterfaces (Research Grants)
  - Researching an adaptive system for tool wear monitoring based on artificial intelligence (Research Grants)
  - Wear protection in rolling bearings by preconditioning of the workpiece surfaces in manufacturing (Research Grants)
  - Modeling of the behavior of elastically bonded tools in gear honing (Research Grants)
  - Derivation of cause-effect relationships for die design on the basis of data-driven process modeling for fine blanking (Priority Programmes)
  - Development of a Greybox model for wear prognosis of PVD coated carbide tools during high performance turning of steels (Priority Programmes)
  - Adaptable tool monitoring systems for turning processes based on inprocess cutting force sensors (Research Grants)
  - Methodology for Generation of Cross-Process Modells (IKTINO II) (Research Grants)
  - Electrochemical wire cutting with axial high-pressure flushing and internally flushed tube tools (Research Grants)
  - Measurement and modeling of geometric accuracy when broaching profile grooves (Research Grants)
  - Modelling of the impact of the thermo-mechanical load collective on the rim zone microstructure when cutting TiAl6V4 (Research Grants)
  - Material removal behavior during grinding of tungsten carbide cemented carbides with multiphase alternative binder materials (Research Grants)
  - Explanatory model for knowledge-based process design in unguided vibratory finishing of WC-Co cemented carbide (Research Grants)
  - Analysis of Thermal Loads in Generating Gear Grinding for Residual Stress Prediction (Research Grants)
  - Quantitative description of the material condition during profile grinding of transformable steels (Research Grants)
  - Mechanism-driven fine blanking of high manganese steel for target-oriented setting of material and sheared part properties (Fine blanking induced plasticity) (Research Grants)
  - Development of a methodology for the evaluation of demand-oriented flexible manufacturing process sequences for variant-rich series production (Research Grants)
  - Analysis of function-oriented surfaces of injection moulding cavities manufactured by electrical discharge machining (Research Grants)
  - Data-driven identification and explanation of process changes due to batch fluctuations on the workpiece and tool side during surface grinding (Research Grants)
  - Data-driven technology development in wire EDM (Data-WEDM) (Research Grants)
  - Analysis of wire breakages in wire electrical discharge machining using electrical signal analysis and high-speed camera analysis (Research Grants)
- Completed projects
  - Enlargement of the forming limits of metal spinning by laser-assistance (Priority Programmes)
  - Untersuchungen zum Kurzzeit-Flüssigphasensintern von Wolframkarbid mit Kobald-Bindephasen durch Laserstrahlung (Research Grants)
  - Uniaxial hydroforming of cold forged cups on single action presses (Research Grants)
  - Wear analysis of glassy carbon in the fused silica molding process depending on the surface quality of the glassy carbon (Research Grants)
  - Blanking of fibre reinforced plastics. Manufacturing technology and numerical modelling (Research Grants)
  - Process Machine Interaction In Gear Honing (Research Grants)
  - Modelling of grinding worm profile wear at generating gear grinding (Research Grants)
  - Development of a model to predict the machining forces in the rolling process of powder metallurgical parts using the example of gears (Research Grants)
  - Grain refinement in the surface layer of metallic materials by means of machine hammer peening (FinePeening) (Research Grants)
  - Influence of the grinding wheel topography on the formation of the thermo-mechanical stress collective in the grinding process (Research Grants)
  - Development and verification of a constitutive approach for the determination of high-strain-rate flow curves by means of the cutting process (Research Grants)
  - Fundamental research on a double beam laser process for metals (Research Grants)
  - Investigation of the thermomechanical interactions in the shear zone during the fine blanking of heated high strength sheet materials (HotFib) (Research Grants)
  - Theory of chip formation in grinding of fiber reinforced ceramics with porous matrix (Research Grants)
  - Development of a Cutting Force Model for the Optimization of the Process Design of Bevel Gear Grinding (Research Grants)
  - Tribological Performance of Rolling Contacts Produced by EDM (Research Grants)
  - Development and industrial application of a model for tool life prediction for multi-flank chip formation by means of bevel gear plunging processes (Research Grants)
  - Theory of chip formation in grinding of biphasic brittle materials using the example of WC-Co carbide (Research Grants)
  - Dry forming of low alloy steels by direct impact extrusion using a self-lubricating tool coating and structured workpieces (Priority Programmes)
  - Characterization and simulation of the fracture behavior of CBN grain types as a function of crystal structure, grain orientation and dressing parameters (Research Grants)
  - Numerical modeling of the thermo-mechanical contact in grinding (Research Grants)
  - Model-based control of surface integrity in hard turning (Priority Programmes)
  - Development of a 3D multiphysics model to analyse the thermo-mechanical effect of coolants in metal cutting (Research Grants)
  - Development of a kinematic model for the prediction of the relative speed between chips and work piece in unguided vibratory finishing process (Research Grants)
  - Methodology for the highly iterative design of production process sequences (Research Grants)
  - Material removal mechanisms in grinding of fiber-reinforced non-oxide ceramics (Research Grants)
  - Investigation of the interactions of incremental surface layer forming and HPPMS coating on fine blanking dies in order to enable a load-applied surface integrity adjustment (TEStOI) (Research Grants)
  - Analysis of material removal mechanisms in grinding of super hard cutting materials regarding polycrystalline cubic boron nitride (PCBN) (Research Grants)
  - Fundamental material based investigations to understand electric discharge machinability of electrically conductive ceramics with oxide matrix (Research Grants)
  - Compensation of Shape and Dimensional Deviations Due to Thermo-Elastic Deformation During Dry Machining (Research Grants)
  - Smooth Particle Hydrodynamic (SPH) Modeling of Grinding the SiC-SiC Ceramic Matrix Composite (Research Grants)
  - Design model for the knowledge-based adjustment of the edge zone and surface properties of additive-manufactured components for guided centrifugal finishing (Research Grants)
  - Microstructure-sensitive fatigue lifetime assessment considering forming history effects (Research Grants)
  - Cost-optimized planning of changes in manufacturing of safety-critical components through systematic manufacturing change management (Research Grants)
  - Product lifecycle-oriented optimization of the manufacturing phase and the use phase of precision tools (Research Grants)
  - Multi-scale modeling of the thermal workpiece load in the turning process considering the cutting fluid (Priority Programmes)
  - Methodology for generating cross-technology metamodels (IKTINO) (Research Grants)
  - Integration of technology and inspection planning for cost-optimized production processes of medical devices (Research Grants)
  - Analysis of discharge-dependent surface integrity of cemented carbide forming dies machined by sinking EDM and its influence on the tribological characteristics and the resulting fatigue behavior (Research Grants)
  - Fine blanking of carbon fibre reinforced plastics (fine blanking CFRP) (Research Grants)
  - Machine hammer peening of laser deposition welded IN718 components (MalIn) (Research Grants)
  - Development of a friction model characterizing the temperature-, relative velocity-, and contact normal stress-dependent behaviors at glass-mold interface in Precision Glass Molding (FriPGM) (Research Grants)
  - Investigation of the cutting mechanisms during ultrasonic assisted machining of fibre reinforced non-oxide ceramics with geometrically defined cutting edge (CMCs) (Research Grants)
  - Interdisciplinary design of components with complex functional surfaces under consideration of manufacturing boundary conditions (Research Grants)
As Leader
- Completed projects
  - Horizontal 5-axis machining centre (Major Research Instrumentation)
As Project Head
- Current projects
  - Simulation-based optimization of the milling process by regulating the tool temperature - knowledge transfer project (CRC/Transregios)
- Completed projects
  - Model and method for the determination and distribution of converted energies in milling processes (CRC/Transregios)
  - Model and method for the determination and distribution of converted energies in grinding processes (CRC/Transregios)
  - Damage influence in deep drawing and stretch forming (CRC/Transregios)
As Ehemaliger Antragsteller
- Current projects
  - Greybox models for in-situ quantification of probabilistic tool life of CVD coated cemented carbide gear hobs (Priority Programmes) (8/2024 - 2/2025)
As Cooperation Partner
- Completed projects
  - Technology development for the efficient production of glass exterior and interior components for automotive futures (Research Grants)

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Professor Dr.-Ing. Thomas Bergs

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Professor Dr.-Ing. Thomas Bergs

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