Against the background of constantly increasing demands on materials and machining processes, the department Grinding and Gear Cutting is concerned with the further development of grinding applications for machining mainly metallic materials and components. The scientific penetration of the mechanisms of action in machining with geometrically undefined cutting edges requires a holistic approach that takes into account specific material properties as well as process kinematics, tool development or the application of process aids.
Simulation as a means of improving process understanding is an indispensable tool in our work. In addition to basic research work, which is funded by the German Research Foundation (DFG), for example, a large part of our research and development work is based on industrial cooperation projects. Scientifically trained and motivated personnel, a modern machine tool park and extensive laboratory facilities form the basis for successful project work.
As often the last step in a longer value-added chain for the production of high-quality components, high demands are placed on the grinding process in terms of processing quality and productivity. In addition, there are demands on the energy and resource efficiency of the processes used. Only through a profound analysis can the interactions between the process design, the material to be machined, the tools used and process auxiliaries be mastered.
In the grinding and gear cutting department, grinding technology research work is concentrated in the Production Engineering department. Basic and applied research work is carried out here with the focus on material-oriented, productive and resource-efficient design of process chains. In this area of conflict, the research and development work combines the materials and process engineering know-how available at the Leibniz Institute for Materials-oriented Technologies. The mature developments are applied in the automotive industry and its suppliers, in aerospace technology and other key industries. In addition, innovations are realized in tool technology, medical technology and machine tool construction.
Vibration-assisted drilling, with its additional axial movement, is investigated with minimum quantity lubrication (MQL). The combination of both technologies improves the drilling process, but also increases the number of process and control variables to be coordinated.
In 2024, the previously developed coupled vibration-assisted drilling model was further developed and used to investigate the wetting of the machining zone and the gas flow dependent chip transport.
Cooperation: Leibniz-IWT VT/FT
Funding: DFG (SPP 2231 FluSimPro)
Contact:
Teresa Tonn
Tel.: +49 421 218 51235
E-Mail: t.tonn@iwt.uni-bremen.de
Based on the process signature concept of the transregional CRC 136, this project aims to develop an assistance system for the detection of undesirable material modifications during surface and profile grinding of hardened steels.
The main objective is to create the basic principles and the subsequent development and testing of a prototype with the industrial partner Blohm Jung GmbH. The assistance system is intended to enable in-process detection of grinding burn and thus of undesirable surface-layer modifications such as tempering zones during surface and profile grinding.
Cooperation: Blohm Jung GmbH
Funding: DFG
Contact:
M.Sc. Nikolai Guba
Tel.: +49 421 218 51143
E-Mail: guba@iwt-bremen.de
The use of oil as a metal working fluid for gear grinding is indispensable. The chemical and physical properties of the oil influence the grinding process and thus the productivity.
The main objective of this project is to investigate the influence of three different grinding oils during discontinuous profile grinding of gears. A suitable oil is to be identified in which the thermal load during the grinding process is as low as possible despite an increasing machined volume. With the help of such an oil, significantly more gears can be ground before thermal damage occurs and the grinding wheel has to be dressed.
Funding: Kooperationsprojekt mit Fa. Master Fluid Solutions WDG GmbH
Kontakt:
M.Sc. Nikolai Guba
Tel.: +49 421 218 51143
E-Mail: guba@iwt-bremen.de
The objective of the project is a systematic investigation of the gear grindability of various case hardening steels. The results offer the potential to coordinate the choice of alloy system and case hardening steel as well as the process design during heat treatment and grinding process in a productivity-optimized manner.
Processing: Leibniz-IWT FT/WT
Funding: FVA Eigenmittel
Contact:
Dr.-Ing. Tobias Hüsemann
Tel.: +49 421 218 51190
E-Mail: huesemann@iwt-bremen.de
This project aims to develop an in-depth understanding of the dynamics, resulting effects, and interactions of minimal quantity lubrication (MQL) in vibration-assisted drilling by numerically modelling the interactions between flow dynamics and chip formation.
Cooperation: Leibniz-IWT FT/VT
Funding: DFG (SPP 2231)
Kontakt:
M.Sc. Lukas Schumski
Tel.: +49 421 218 51152
E-Mail: schumski@iwt-bremen.de
In this practice-oriented study, the question of the correlation between the process parameters as well as the system parameters and the residual stresses that occur after fine machining is systematically analyzed. Using different grinding wheel specifications with an elastic bond system, the limits of machining for the surface integrity properties are analyzed.
Funding: FGS – Forschungsgemeinschaft Schleiftechnik e. V.
Kontakt:
Dr.-Ing. Tobias Hüsemann
Tel.: +49 421 218 51190
E-Mail: huesemann@iwt-bremen.de
In the transfer project T07, an increase in the mechanical load in the process is to be achieved by adjusting the grinding wheel.
As a grain shape with the largest possible rake angle, it was shown that with a spherical grain there is potential for subsurface layer strengthening by setting favorable residual compressive stresses. In addition to the surface and subsurface properties, the roughness of the components is also considered, as this also significantly determines the functional properties. The theoretical considerations are supported by simulation models and grinding tests.
Cooperation: Artifex Dr. Lohmann GmbH & Co. KG
Funding: DFG
Contact:
Dr.-Ing. Tobias Hüsemann
Tel.: +49 421 218 51190
E-Mail: huesemann@iwt-bremen.de
The aim of this project is to develop a model that systematically includes the influence of previous process steps on the subsurface depth modification into the design of the grinding process cycle. This should contribute to an optimized material removal distribution and thus to an increase in productivity through reduced process times.
The thermochemical heat treatment nitriding is used to improve the surface properties of a workpiece by diffusing nitrogen into the surface layer to form precipitates. In tool manufacturing, these precipitates are used to increase the hardness and wear resistance of forging dies at elevated temperatures and thus their service life.
As no further finishing steps take place after nitriding, the tools are finished by grinding in their hardened or tempered state. During this hard finishing process, the workpiece surface layer is affected by the interaction of the material with the grinding tool and the metal working fluid as well as the thermomechanical load, which in turn affects the surface structure of the workpiece and thus the nitriding response. In this research project, the relationships between the design of the grinding process, the changes in the surface layer and the final nitriding treatment are investigated.
Cooperation: Leibniz-IWT WT/FT
Funding: BMWK-AiF/IGF (AWT)
Contact:
M.Sc. Nikolai Guba
Tel.: +49 421 218 51143
E-Mail: guba@iwt-bremen.de
Aim of this project is the investigation of so far unknown effects on the micromagnetic detection of thermo-mechanical surface damages at ground gear flanks. Based on previous projects, investigations are carried out on profile and generating ground gears from case-hardening steel 20MnCr5 in different heat treatment conditions.
Cooperation: Leibniz-IWT WT/FT
Funding: BMWi-AiF/IGF (FVA)
Kontakt:
M.Sc. Nikolai Guba
Tel.: +49 421 218 51143
E-Mail: guba@iwt-bremen.de
The aim of this project is to demonstrate that the technological process window for discontinuous profile grinding of load capacity-optimized gears can be extended by using a metal working fluid supply that is adapted to the grinding wheel structure.
To this end, the influence of different grinding wheel structures on the grindability of load capacity-optimized gears and their interaction with the fluid jet is to be systematically investigated and the fluid supply optimized based on the results obtained.
Funding: BMWK-DLR/IGF 23195 N/FVA 1023 I
Kontakt:
M.Sc. Lasse Jakob Arera
Tel.: +49 421 218 51144
E-Mail: arera@iwt-bremen.de
This three-year project aims to investigate the potential for energy and resource savings in grinding processes. Optimization is achieved by adapting the metal working fluid supply. In the further course of the project, the recycling potential of the resulting grinding sludge will also be investigated.
Cooperation: QSIL Ingenieurkeramik GmbH, Lightway GmbH, Spreyer Werkzeug-Technik GmbH, Esgemo Schmierstofftechnik GmbH & Co KG, Präzisionsmaschinenbau Bobertag GmbH
Funding: BMWK, PTJ
Contact:
B.Sc. Mona Cordes
Tel.: +49 421 218 51124
E-Mail: cordes@iwt-bremen.de
In this project, the potential of a grinding process control based on a soft sensor was shown. The soft sensor combines a thermal limit depending on specific grinding power and contact time with the in-process measured Barkhausen noise.
Cooperation: Leibniz-IWT WT/FT, Fraunhofer IWU Chemnitz
Funding: DFG (SPP 2086)
Contact:
Dr.-Ing. Jérémy Epp
Tel.: +49 421 218 51335
E-Mail: epp@iwt-bremen.de
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