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Development and optimization from Processes

  • Reliable, mastered and effective manufacturing methods establish the “enabling technologies” needed for new innovative products. Geometric complexity, exploitation of the materials properties which is often associated with processing difficulties, together with automation and economic efficiency places enormous demands on manufacturing. Process know-how is the key technology for products of the future. 
  • In terms of removal methods, we can differentiate between chipping processes with defined (turning, drilling, milling, etc.) and undefined cutting edges (grinding, honing, broaching of hardened materials, etc.) as well as other physical processes. These include electrical discharge or electrochemical machining and hybrid processes as a combination of, for example, ultrasonic with chipping. Further methods base on water jet or laser beam. Alternatively to the material subtracting methods we have the adding process technologies or generative methods like selective laser sintering (SLS), selective laser melting (SLM), metal and 3D printing, laser deposition welding, dimensioning and production of fibre reinforce components and assembly techniques with and without permanent connections. Due to the size effects, microprocessing often differs from that of classical component sizes.
  • Common needs for processes are methods to characterize and simulate. In addition to offline measurements on the work piece and tool, for example for roughness and wear, systematic measurements (force, acoustic emissions, temperature, pressure, chip length, etc.) are required during processing. This is not only designated for process investigations but rather also for the monitoring of processes and manufacturing equipment for automated unmanned production. Alongside simulation, there are simple phenomenological models, very complex methods like nonlinear finite element or particle methods.

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