Exploitable results
Today the high precision manufacturing of components used in the car industry is mainly done through grinding and honing involving coolants that have negative economical and ecological aspects. An alternative machining technology is high precision machining with geometrical defined cutting edge tools. These avoid use of cutting fluids and in addition give high process reliability and flexibility. The results and the knowledge from machining tests were used to develop machining strategies and allow the selection and optimization of the technological parameters for Technical Demonstrators for the fine boring, milling and turning process. The initial tasks involved the development, verification and testing of the technical demonstrators to determine the reachable surface quality, accuracy of shape and tolerances of the newly developed demonstrators. For that purpose the technical demonstrators were investigated (eg spindle run-out, position accuracy and thermal behaviour) before the tests with the specimens supplied by the industry partners were carried out. Various components (eg engine blocks, camshafts) with various workpiece materials (eg aluminium, cast iron) were machined on conventional (state-of-the-art) machines and on the technical demonstrators, to compare the results especially regarding the specifications given by the automotive industry for high precision components.
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