Laboratory for cutting machine tools

Learning production technology in a practical way

Teaching

The laboratory for cutting machine tools offers various laboratory exercises every semester for students from MAB/PS (6th semester) and as part of a mandatory elective module.

The individual laboratory topics are:

Fixture construction (clamping a workpiece for machining on a milling machine)
Turning and burnishing (CNC turning with different feed rates followed by burnishing to produce surfaces in the range of Rz 1 μm. Such processes occur in many areas of industrial manufacturing (e.g. hydraulic cylinders),
Hard turning and grinding of a hardened component (comparison of the two processes used in industrial manufacturing to produce highly stressed precision components such as gear shafts or expansion screws),
Force measurement and chip formation during turning (to determine the energy conversion during turning (Kienzle's cutting force relationship) and chip formation with different manipulated variables of the process and
Gear machining (manufacturing and testing a gear by hobbing and profile milling).

Interesting measurement technology at the LSW

Röntgendiffratometer während der Messung

X-ray diffractometer

The necessary increase in the power density of drive systems, both through weight reduction and improved materials, is leading to ever higher demands on manufacturing processes.

Since 2011, the laboratory for cutting machine tools has been using an X-ray diffractometer from Stresstech to measure residual stresses in crystalline materials in order to identify correlations between the process control of various manufacturing methods and the strength behaviour of highly stressed components (drive axles, gears, expansion bolts, etc.). The atomic distances at depths of a few micrometres below the surface are measured with "soft" X-rays and the stress states in the material are determined,

Confocal microscope

Since 2016, the laboratory for cutting machine tools has owned a confocal laser scanning microscope VK-X150 from KEYENCE. This allows surfaces to be microscoped with a resolution in the nanometre range, visually displayed and digitally measured.

Equipment

Turning

CNC lathe machine GILDEMEISTER CTX400 (2001)

Cycle-controlled DMT/KERN CD322 (2016)

PITTLER automatic lathe machine (approximately 1960)

Milling

5-axis milling machine of SPINNER VC360 (2010/2016)

3-axis milling machine KUNZMANN WF600MC

with electronic dividing head (2016)

Gear hobbing

PFAUTER gear hobbing machine (approximately 1960)

UNION (1952)

Smoothing and deep rolling

Various tools by ECOROLL

Grinding

Surface grinding – GEIBELandHOTZ FS640Z (2016)

External cylindrical grinding – ROT CNC with hydrostatic grinding spindle (2014/2016)

X-ray diffractometer

for the determination of residual stresses and retained austenite in metallic materials STRESSTECH G2 (2011)

Force measurement

for the determination of machining forces: div. KISTLER

Length measurement

non-contact displacement measuring systems from μ-EPSYLON, WAYCON

Surface analysis

tactile roughness measuring devices from MAHR and TAYLOR HOBSEN

3D microscopy

high-resolution digital confocal microscope from KEYENCE VK-X100

Modal analysis

wave analyser (M+P)

Component strength

4-point rotating bending test bench POWER ROTABEND (SincoTec)

Balance technology

Analysis of imbalances (e.g. grinding wheels) PROFILINE (MPM)

Research

Since 2010, various research projects have been carried out in the

Department of

Machining Tools, Production Technology, Assembly and Quality

together with companies from the region (also bilaterally).

Publicly funded projects under the direction of Prof. Lierse:

InnoDressTec - Innovative concept for dressing ceramic bonded grinding wheels
BMWi/ZIM - together with DR. KAISER DIAMANTWERKZEUGE, Celle - Duration: 2013-2015
Objective: Research into new parameter limits for the use of a new generation of dressing tools in the dressing of conventional grinding wheels.

FeWaZahn - Inline hard rolling of gear root areas to increase load capacity
BMWi/ZIM - together with ECOROLL AG, Celle and SINCOTEC, Clausthal Zellerfeld - Duration: 2015-2017
Objective: Within the project, a tool system for inline deep rolling of the tooth root area of straight-toothed gears was developed,
in order to induce higher residual compressive stresses than shot peening and to increase the tooth root load capacity.

ReduStressGear - Development of an innovative method for process-dependent control of a dressing spindle system for the reduction of
tensile residual stresses during tooth flank profile grinding
BMWi/ZIM - together with DR. KASIER DIAMANTWERKZEUGE, Celle - Duration 2016-2019
Objective: Within the scope of the project, a novel process strategy for dressing profile grinding wheels will be developed.
MikroReib - microstructure grinding of tribologically highly loaded crankshafts for friction reduction
EFRE - together with BÜCKER UND ESSING, Lingen - Duration: 2018-2020 - mikroreib.wp.hs-hannover.de
Objective: In the project, high-hardness crankshaft bearing seats are microstructured by a grinding process in order to improve the friction conditions
of plain bearing seats by means of improved lubricant film formation.

As well as bilateral, directly funded projects:

Influence of different abrasive grain qualities and dressing regimes on the formation of residual compressive stresses on ground workpieces - FGS - Forschungsgemeinschaft Schleiftechnik e.V.
Various industrial projects

The two research assistants Timo-Rouven Kaul and Steffen Schulze are doing their doctorates at the University of Magdeburg under Prof. Dr.-Ing. habil. Prof. h.c. Dr. h.c. Dr. h.c. B.Karpuschewski (now University of Bremen).

The

Department of Machine Tools, Production Technology, Assembly and Quality

and the

laboratory for cutting machine tools

participate in the

Research Cluster Industry 4.0

of the Hochschule Hannover – University of Applied Sciences and Arts forschungscluster.hs-hannover.de/industrie-40/.