Ziel
Two new ultrafine carbide grades were successfully developed. A lot of effort was given to optimise the geometry of these new carbide grades for drilling operations in Al-alloy with external and internal minimum lubrication. All tools were used without coating. Laboratory testing with internal minimum lubrication revealed that straight fluted drills are only suitable at lower cutting parameters. If higher cutting parameters are desired, the drill has to have a spiral flute. The build-up edge especially in the tool centre was also found to be much smaller on the tools with the exit of the cooling channels in the clearance. For a drilling depth of more than 5 times the diameter, internal minimum lubrication is recommended. Both carbide grades are suitable for aluminium machining. Field-testing, in order to verify the functionality of the new developed carbide grade SMG13, was successful. No problems or disturbance factors could be noticed. Drilling in AlSi(9)Cu(3) with internal minimum lubrication under production like conditions is feasible with uncoated ultrafine carbide grade drills. In the field tests, the straight fluted drill was found to give a better hole; less variation in diameter, better cylindricity, better roundness and better surface finish than twisted drills.
The drilled holes were used to field test symmetric as well as asymmetric coated reference forming taps with internal minimum lubrication in AlSi(9)Cu(3). The tests revealed no difference in performance between the symmetric and asymmetric forming taps, both giving an approved M7 thread. Therefore, tapping in AlSi(9)Cu(3) with internal minimum lubrication under production like conditions is feasible.
Different ceramic-metal composite grades were specifically developed to compete with HSS tools for tapping steel. Optimisation of the tap geometry significantly increased the lifetime of the tools, but not yet enough to economically compete with reference HSS-taps. The variation in tool life of the initially developed grade is high but the average tool life, 2459 holes, is clearly higher than the average tool life, 304 holes, of the reference carbide grade. The potential of the new grade is obvious but at this stage, it is not suitable for a save production, due to the large scatter in tool life. Compared to the initially developed grade, the tool life of the later grade taps is shorter but the scatter in tool life was reduced to a much more reasonable value. A further optimisation will continue after the project.
MTCVD multilayer coatings were developed and their performance was compared with commercially available Alox and Fire+Movic coatings. The coatings were applied on reference grade carbide drills and tested in 42CrMo4 steel. The tool life of the MTCVD coated tools was found to be lower than that of the already existing coatings.
The geometry of reference grade carbide tools was optimised and a suitable coating was applied for drilling operations in C70 steel connecting rods. Laboratory testing revealed that the geometry of the tools for the machining of C70 connecting rods is satisfying and the wear of the tools in C70 connecting rods is very low. HSS taps with optimised geometry and suitable coating were tested with internal minimum lubrication in C70 con-rods. The taps with optimised geometry almost reached the same tool life as the actually achieved tool life with state-of-the-art taps during wet machining.
Field testing revealed that drilling and tapping in AlSi(9)Cu(3) with internal minimum lubrication under production like conditions is feasible. Moreover, preliminary tests to check the possible to machine cylinder heads in a real production line under minimum quantity lubrication conditions, even without optimised tools, revealed that the results were as good as in the normal wet production of parts. Despite the fact that only a few parts were machined, the results are very promising. Therefore, dry machining, or the use of the MQL technique from now on is considered in all projects. Field testing of drilling operations in St44 steel and GG20 grey cast iron with optimised coated reference carbide drills under dry conditions revealed a strongly reduced cost and significant increase in tool life as compared to the current wet machining with currently used tools. The costs/hole for a drilling operation in St44 steel could be reduced from 0.153 to 0.124 Euros. The biggest savings re established in the cooling costs. The results obtained were very good and the application of the external beam sparkling technique is very promising.
Two completely new classes of ceramic composites, e.g. ZrO(2)-based and SiAlON-based were developed. The obtained results showed that it was possible to improve especially the fracture toughness of the sialon matrices by the addition of non-oxide secondary phase additions. The improved mechanical properties however were not good enough for the composites to be promising candidate materials for complex tools. On the other hand, ZrO2-based composites with non-oxide secondary phase additions were developed, offering a range of ceramic composites with excellent fracture toughness and strength in combination with a wide hardness range. Moreover, carefully prepared ZrO(2)-based composite powder mixtures could be successfully densified using existing Sinter-HIP furnaces, allowing the preparation of drill blanks. The chemical compatibility of the newly developed materials was compared with coated and uncoated state-of-the-art cutting tool materials by means of static interaction couples with 42CrMo(4) steel and AlSi(9)Cu(3) alloys. A number of experimental ceramic composites were selected for experimental turning tests with 42CrMo(4) steel and AlSi(10)MgMn. Some of the experimental ZrO(2)-based composites are suitable for turning 42CrMo(4) steel at 300 and 500 m/min. At a cutting speed of 300 m/min, the tool life of some ZrO(2)-based composites is superior to that of commercial Al(2)O(3)-based CC650 and CC620 cutting tools. Preliminary testing revealed that high speed dry drilling in grey cast iron is feasible with certain composite grades.
An extensive summary of the available external and internal "Semi-dry" techniques available on the market was made, and emerging trends were highlighted. Most of these techniques were studied and tested. With respect to drilling with the internal minimum lubrication technique, a number of oils were tested revealing that saturated alcohols and fatty alcohols are the best suitable oils for MQL.
The chip evacuation problems from the machine and from the clamping fixtures were studied from tests performed on a new completely dry transfer line machine and on a "1g-XL" module retrofitted for dry HSC technology. The attention was focussed on clamping fixtures, beds, spindles, lubricant system, and pneumatic system. Most of the results and guidelines originated from these preliminary studies resulted in final drawings for machine construction. The beds and clamping fixture architecture for transfer-line machines, and the pallet exchanger for stand-alone modules have been investigated.
The heat transfer reduction and thermal compensation problem involved in dry or semi-dry machining was studied on transfer-lines and stand-alone modules. On dry transfer line machines, the transfer bar, the grease of the spindles and the rubber fittings of the pipes of the dust extractor system were identified as critical items. In the new concept developed for dry and semi-dry machining, the transfer bar is no longer a completely rigid structure, but is divided into rigid segments. A thermal surveys during metal cutting tests on a "1g-XL" stand-alone module revealed that the temperature increase on the tool, tool holder, spindle and the element was quite acceptable, indicating that a new structure designed basically for dry and semi-dry operation, with an optimal chip evacuation, does not need any thermal compensation system. It should however be clear that stand-alone modules have very different configurations, and that milling operations, producing a huge amount of chips, were not investigated.
The dry or semi-dry machining technology was implemented to a high speed machine demonstrator "1g-XL". Therefore, a new electro-spindle was designed, produced and installed. The new spindle allows conventional wet machining with high-pressure coolant through the spindle up to 80 bar, outside mixed minimum lubrication up to 16,000 rpm and completely dry machining up to 16,000 rpm. The available minimum lubrication technologies were evaluated and a TKM aerosol booster was selected and installed. Some solutions to retrofit the structure of "1g-XL" module in order to facilitate the chip evacuation from the clamping fixtures were investigated. The reliability of the new technologies was tested and evaluated for drilling, tapping and reaming operations on cylinder heads (Al-alloy) and drilling and tapping operations on con-rods (C70 steel). The results of the cylinder head trials revealed that the quality of the holes is perfectly comparable to that under conventional wet machining. The results on the con-rod machining were very interesting, the tolerances were respected and the quality of the threaded hole is good.
Based on the requirements with respect to chip evacuation and thermal compensation, new machine architectures and new process strategies for dry cutting conditions were developed. A new pallet exchanger with vertical rotation table was developed and a preliminary project for a transfer-line machine without transfer bar was started. With respect to the architecture of stand-alone modules, the considerations pushed the development of a completely new module, called "MT3". This configuration has the advantage to be fully applicable both in transfer-line machines and as a machining centre, and to be fully usable for high-speed dry cutting. Other feasibility studies concerned machining centres with only two axes. Two preliminary layouts are ready and the idea to develop these modules after the end of the project is being evaluated.
The objective of the project is to develop new cutting materials, tools and machine tool technologies for low cost chip generating operations by reduction of the cost of the use of cutting fluids (cooling lubricants) in selected but yet broadly applicable machining operations within the interests of the end users of the consortium. More specifically the aim will be the implementation of dry high speed machining or where this proves to be impossible, the use of "nearly dry" techniques.
Since dry machining is already state of the art in turning and milling for a range of workpiece materials, the project is aimed specifically on drilling, reaming and tapping, which are often critical when a workpiece is to be machined completely dry. The materials to be machined have been selected by the end users in the consortium to be aluminium silicon alloys and steels. These endusers include a representative of the automotive industry, thus assuring the economic impact of the project, as well as a manufacturer of equipment for the paper industry.
The critical issues in dry machining will be addressed including the development of cutting materials and appropriate coatings, the design and testing under field conditions of tools for drilling, reaming and tapping, the development of new machine concepts and machine designs in particular the study of chip removal techniques in dry or nearly dry machining and the control of heat load on machine and workpiece. Economic studies as well as the implementation of an expert system will prepare the exploitation of the results of the project.
Targets set for the properties of cutting tool materials to be developed depend somewhat on the particular class of materials but in general a minimum hardness of 1500 Vickers and a minimum toughness of 8 MPa m% is thought necessary for the intended applications; Chemical compatibility with the workpiece material will be another be it difficult to quantify attribute of the new materials and coatings systems. CVD, MTCVD and PVD coating technology will be used. A total of 12 new materials or material/coating combinations are to be developed. About 870 tools will be produced and tested. The
accompanying research on shape of the tool and on machining conditions is expected to lead to the following productivity increases for drilling in steels a factor of 4 and in A1Si a factor of 8.
It is expected that new materials and coatings can be brought to market after one to two years. Prototype tools will be available but further testing to determine optimum working conditions on workpiece materials will be necessary before introducing these tools as standard products on the market (estimated time 2 years). The feasibility of new technology for dry or nearly dry machining is expected to have been demonstrated. It is estimated that another 1 to 2 years will be necessary to bring new machining modules for high speed dry machining to market.
Wissenschaftliches Gebiet (EuroSciVoc)
CORDIS klassifiziert Projekte mit EuroSciVoc, einer mehrsprachigen Taxonomie der Wissenschaftsbereiche, durch einen halbautomatischen Prozess, der auf Verfahren der Verarbeitung natürlicher Sprache beruht. Siehe: Das European Science Vocabulary.
CORDIS klassifiziert Projekte mit EuroSciVoc, einer mehrsprachigen Taxonomie der Wissenschaftsbereiche, durch einen halbautomatischen Prozess, der auf Verfahren der Verarbeitung natürlicher Sprache beruht. Siehe: Das European Science Vocabulary.
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Finanzierungsregelung (oder „Art der Maßnahme“) innerhalb eines Programms mit gemeinsamen Merkmalen. Sieht folgendes vor: den Umfang der finanzierten Maßnahmen, den Erstattungssatz, spezifische Bewertungskriterien für die Finanzierung und die Verwendung vereinfachter Kostenformen wie Pauschalbeträge.
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