High-speed camera for a special machine for chip formation analysis

• Subject Area: Production Technology
• Term: since 2026
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 584437478

Imaging systems such as high-speed cameras make a significant contribution to gaining insights in fundamental research. This also includes the investigation of the chip formation process, where highly complex interactions between the tool, material, cooling lubricant, and surrounding medium take place within a few milliseconds. A detailed understanding of these processes is of fundamental importance for the development of new cutting materials, coatings, material alloys, or cooling lubricant technologies. The new measurement technology to be integrated into the machine for analyzing chip formation using high-speed videography enables high-resolution recordings of the chip formation process, which includes not only material deformation but also coolant distribution and the interaction between tool and material. By using suitable lenses, the working area can be enlarged and uniform illumination achieved using special lighting technology. This enables the capture of high-quality images that not only provide fundamental insights into the mechanisms of chip formation, but also serve to validate numerical simulations. In addition, the high-resolution image data, in combination with suitable analysis software, allows the use of methods such as digital image correlation (DIC) and particle image velocimetry (PIV). This allows state variables to be calculated directly in the chip formation zone and material models for chip formation simulations to be precisely calibrated. The compact test setup and simple kinematics of investigations in orthogonal cutting on the special machine used at the ISF for chip formation analysis enable comparatively simple integration of measurement technology and resource-saving test execution. The findings from orthogonal cutting tests can be transferred to any machining process with a geometrically defined cutting edge. The proposed measurement technology is therefore of great scientific relevance due to the expected gain in knowledge and will be used in numerous research projects in the future to investigate the fundamental mechanisms of machining.

• DFG Programme: Major Research Instrumentation
• Major Instrumentation: Hochgeschwindigkeitskamera für eine Sondermaschine zur Spanbildungsanalyse (Erneuerung)
• Instrumentation Group: 5430 Hochgeschwindigkeits-Kameras (ab 100 Bilder/Sek)
• Applicant Institution: Technische Universität Dortmund
• Leader: Professor Dr.-Ing. Dirk Biermann