Batchprocessed flexible micro grinding tools for end maching of metallic surfaces

• Applicant: Professor Dr.-Ing. Marc Christopher Wurz
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering ; Synthesis and Properties of Functional Materials ; Production Automation and Assembly Technology
• Term: from 2019 to 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 418797794

• Final Report Year: 2024

Final Report Abstract

Technological progress requires ever more precise components. For example, a higher surface quality (Ra < 0.2 µm) improves, among other things, reflection in the optical range and, in the mechanical range, the contact surface, the friction values and the corrosion resistance. Such an increase in the functionality of construction components and connecting elements requires new cutting tools for machining ductile materials. Within the project, the production of a micro-grinding tool with a flexible bonding matrix for finishing copper will therefore be investigated. The aim here is to analytically and empirically investigate the relationships between the manufacturing process and the application behavior of the new tools. The manufacturing process was investigated by varying the process parameters and analyzed to determine an optimized selection of manufacturing parameters (25 m%; 1,000 rpm; 450 s; 350 °C). The micro-grinding tools with a circular structure were used to create high surface finishes on copper surfaces. Silicon carbide proved to be the most efficient abrasive, along with cubic boron nitride and diamond, although the type of grain had no influence on linear tool wear. Optimized grinding parameters (20,000 rpm; 100 mm/min; 5 µm) for reducing tool wear were determined by statistical evaluation in parameter variations. Multiple grinding increased the achievable surface quality in the grinding process and was modeled empirically. Further improvements were demonstrated by developing a device for superficial anodic oxidation of the workpieces within the machine tool. Roughness of Ra = 0.06 ± 0.02 µm and Rz = 1.10 ± 0.35 µm was achieved. Despite achieving the project goal of researching a new, efficient micro-grinding tool for machining ductile materials, the applicability of the tool was limited when it came to curved free-form surfaces in 3-axis machining.

Publications

• Application of batch manufactured flexible microgrinding tools on copper and oxidized copper surfaces, 63. Tribologie-Fachtagung, Göttingen, 2022.
  Steinhoff, L.; Dencker, F. & Wurz, M.C.
  
• Herstellung und Evaluierung von Mikroschleifstiften, Produktionstechnik Hannover informiert (phi), Nr. 36, 2022
  Steinhoff, L.
  
• Production and characterisation of batch manufactured flexible micro-grinding tools for finishing metallic surfaces, euspen’s 22nd ICE, Genf, 2022,
  Steinhoff, L.; Dencker, F. & Wurz, M.C.
  
• Application of batch manufactured flexible micro-grinding tools on copper and oxidized copper surfaces. Tribologie und Schmierungstechnik, 70(1), 5-10.
  Steinhoff, Lukas; Dencker, Folke & Wurz, Marc Christopher
  
• Detailed characterisation of batch-manufactured flexible micro-grinding tools for electrochemical assisted grinding of copper surfaces. The International Journal of Advanced Manufacturing Technology, 128(5-6), 2301-2310.
  Steinhoff, Lukas; Ottermann, Rico; Dencker, Folke & Wurz, Marc Christopher