"Turning processes – new compact process chains and

F R A U N H O F E R I n s titute for P ro d uction techno l o g y I P T
Turning processes – new compact
process chains and combinations
Advantages of turning process
combinations
T h e F r a u n h o f e r I P T d e v e l o p s i d e a s a n d solutions for new combinations and chains of processe s involving
t u r n i n g . B y co m b i n i n g h o n i n g a n d p o l i s hing with hard tur ning, it becomes possible to apply the technolo g y i n n e w w a y s t o h a rd a n d h a rd e n e d steels and cemented carbides to achieve optical surfaces. When
h i g h - p e r f o r m a n c e t u r n i n g i s c o m b i n e d with 5-axis milling, it becomes possible to process even hard to
m a c h i n e m a t e r i a l s w i t h o u t a m a c h i n e c hange.
T h e a i m o f o u r re s e a rc h i s t o p ro d u c e components with better tolerances and surface qualities in less
t i m e . T h i s i s a c h i e v e d b y i n t e g r a t i n g t h e aforementioned process combinations into one lathe, which also
m a k e s i t p o s s i b l e t o m a c h i n e t h e w o r k p iece without the need for re-clamping.
High-precision hard turning & honing / High-precision
High-performance turning
hard turning & polishing
Only materials like titanium alloys, titanium aluminides and
For many applications, hard turning provides an interesting
nickel-based alloys are used in the manufacture of compo-
alternative to grinding techniques. Advantages that are spe-
nents for turbo-engine applications – all materials with low
cific to the process, such as short set-up times, dry processing
thermal conductivity and high heat-resistance that are hard to
capabilities and a high degree of flexibility, make hard turning
machine. Over the last few years, the Fraunhofer IPT has built
techniques relevant, not only for the conventional field of
up outstanding expertise in the 5-axis milling of these materi-
individual products and small series production but also for
als. The analysis and optimization of NC data are essential
mass production applications.
here – including the continuous analysis of the kinematic and
dynamic properties of the machines and controls.
Most machining is performed on hard and hardened steels
as well as cemented carbides. The range of products consists
We transfer the available knowledge to the turning process
of bearing components, pneumatic and hydraulic parts and
and optimize the combination of turning/5-axis milling for
chip-free forming tools. By optimizing the process (in terms of
the manufacture of turbo engine components. The ability to
cutting material, process parameters, machining strategy) to
process such components in just one machine also eliminates
improve the results, it becomes possible to achieve accuracies
long, unproductive periods due to machine changes.
from IT3 to IT5 and surface qualities Rz of less than 1 µm.
The combinations of hard turning/honing and hard turning/
polishing developed by the Fraunhofer IPT achieve surface
roughness values of up to optical qualities (Ra < 20 nm).
Our offer
Our machining equipment
In our approach to technology-oriented process design,
Three high-precision hard turning lathes (Hembrug)
we combine technological knowledge and experience with
manufacturing-orientated technology assessment. We help
• Slantbed on natural granite base
you to improve your production processes and process chains
• External electric and hydraulic supply unit
in terms of technical and economic criteria.
• Integrated temperature-controlled coolant supply
• Hydrostatic bearings for spindle and support
Our range of services in the field of turning includes
• Spindle run-out accuracy < 0.1 µm
• Repeatability accuracy < ± 0.1 µm/150 mm
• Processing trials
• Positioning accuracy < 0.1 µm/150 mm
• Feasibility studies
• Integrated honing device (Hembrug 50 CNC)
• Technology development
• Integrated polishing spindle (Hembrug 100 CNC)
• Process development, process design and process optimization
• Manufacture of prototypes and small sized batches
Monforts Unicen 1000 Multiturn
• Help for industrial-scale implementation
• Swing
Sophisticated equipment in conjunction with comprehensive
– above bed 1 000 mm
measuring and analysis facilities and software tools enables
– above cross slide 800 mm
the Fraunhofer IPT to process and evaluate complex, high-
• Machinable length 1 500 mm
precision components made of almost any material:
• Compound slide rest X, Z and Y axis
• Interpolating B-axis
• Hard and hardened steels
• Head with holder for static and powered tools
• Cemented carbides
• Tool magazine (chain magazine) for 34 tools
• Titanium and titanium alloys
• High-pressure cooling at 350 bar
• Nickel-based alloys
• Tool and part measurement system
• Non-ferrous metals
• Main and opposed spindle
We can machine components ranging from the smallest chuck
components to parts of up to 1 000 mm in diameter and
1 500 mm in length.
Fraunhofer Institute for
Production Technology IPT
Steinbachstrasse 17
52074 Aachen
Germany
Phone +49 241 8904-0
Fax +49 241 8904-198
info@ipt.fraunhofer.de
www.ipt.fraunhofer.de
Contact
Dr.-Ing. Thomas Bergs
Phone +49 241 8904-105
Fax +49 241 8904-6105
thomas.bergs@ipt.fraunhofer.de
Dipl.-Ing. Jens Helbig
Phone +49 241 8904-136
Fax +49 241 8904-6136
jens.helbig@ipt.fraunhofer.de