SPP 2086:  Surface Conditioning in Machining Processes

• Subject Area: Mechanical and Industrial Engineering ; Construction Engineering and Architecture ; Computer Science, Systems and Electrical Engineering ; Materials Science and Engineering ; Mathematics
• Term: since 2018
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 359102403

It is the goal of the priority programme to control the surface states of metallic components during end machining operations with mechanical, thermal or chemical main effects, in order to guarantee an enhanced component life and reliability. The realization of dynamic process controls is pursued by the help of in-process soft sensors, which are characterized by a model-based process knowledge. The corresponding scientific questions can only be answered successfully by a joint cooperation of manufacturing, measurement and material technology. This will result in completely new specifications for the actuating variables of the machining processes. The manufacturing technology should in a first step develop a dynamical model of the machining process and the environmental conditions, particularly regarding the effects on the surface states. The task of the material technologies is the material state modelling with regard to the effects of the machining processes. The measurement technique however investigates sensors for the direct and indirect identification of surface states, as well for the identification of input factors which affect the machining process. In a second step the developed material and process models are to be combined with the sensors, which were developed by the measurement technology, in order to realize intelligent soft sensor structures. After the process integration of these soft sensors and the automated control of the machining process actuating variables, the conventionally fixed definition of process parameters can be replaced by a process control, based on the command variables component geometry and required surface state.

• DFG Programme: Priority Programmes

Projects

• Coordination Funds (Applicant Schulze, Volker )
• Deep hole drilling using senor integrated tools to adjust defined functional characteristics into the near-surface peripheral zone (Applicants Möhring, Hans Christian ;  Weihe, Stefan )
• In-process softsensor for surface-conditioning during longitudinal turning of AISI 4140 (Applicants Lanza, Gisela ;  Schulze, Volker ;  Wolter, Bernd )
• Intelligent sensor system for the disturbance variable invariant conditioning of residual stresses during machining of Ti-6Al-4V - Phase 2 (Applicants Heizmann, Michael ;  Zanger, Frederik )
• Model-based control of surface integrity in hard turning (Applicants Bergs, Thomas ;  Münstermann, Sebastian )
• Model-based identification of surface properties during the milling process of Ti-6Al-4V (Applicants Krempaszky, Christian ;  Zäh, Michael Friedrich )
• Prediction of surface conditions for robust control of a turning process based on in-process data acquisition and data driven soft sensor approach (Applicants Kroll, Andreas ;  Niendorf, Thomas ;  Zinn, Wolfgang )
• Process-integrated measuring and control system for the determination and reliable generation of functionally relevant properties in surface edge zones during BTA deep-hole-drilling (Applicants Biermann, Dirk ;  Walther, Frank ;  Zabel, Andreas )
• Process-reliable adjustment of subsurface zone properties in the machining of high-strength and ductile steels using an adaptive manufacturing system (Applicants Breidenstein, Bernd ;  Denkena, Berend ;  Maier, Hans Jürgen )
• Soft sensor technology for the process-integrated influence of the structural fatigue strength by turning of aluminium (Applicants Lampke, Thomas ;  Schubert, Andreas )
• Targeted surface conditioning of 100Cr6 during cryogenic hard turning by means of model-based open- and closed-loop process control (Applicants Aurich, Jan C. ;  Beck, Tilmann ;  Seewig, Jörg )
• Targeted surface layer properties by in-process-monitoring and adaptive process control during grinding (Applicants Dix, Martin ;  Epp, Jérémy ;  Karpuschewski, Bernhard )
• Wear-compensating machining of nanocrystalline surface layers through spatially resolved measurement of temperature and wear (Applicants Bräuer, Günter ;  Schulze, Volker )

• Spokesperson: Professor Dr.-Ing. Volker Schulze