Projects

Das Projekt adressiert Hochsicherheitslabore und Produktionsanlagen, bei denen Wanddurchführungen für notwendige Versorgungsleitungen zu 100 % dicht sein müssen. Dafür soll basierend auf der im vorläufigen ZIM-Projekt „fefodicht“ entwickelten Verklebung von Wanddurchführungen eine neue Applikation entwickelt werden.

Dabei steht die Entwicklung folgender neuartiger Komponenten im Mittelpunkt:
• Modifizierung eines 2-Komponenten-Klebstoffs mit Langzeitresistenz gegenüber gefährlichen Gasen bzw. kontaminierter Luft
• Entwicklung einer Grenzfläche Klebstoff/ Rohrwand, die das Durchdiffundieren verhindert
• Entwicklung einer stabilen inerten Gasatmosphäre mit Überdruckfunktion im Innenraum der Klebeverbindung
• Entwicklung einer Zweifach-Sensorik durch Online-Messung von Leckagen

Als Ergebnis entsteht eine Mediendurchführung mit einer Sensorik und einer kleinen Überdruckkammer. Durch die neue Klebetechnologie soll die Dichtheit gewährleistet und mittels der Überdruckmessung geringste Ausströmungen erkannt und sofort signalisiert werden.

Dieses Projekt wird vom Bundesministerium für Wirtschaft und Energie (BMWE) aufgrund eines Beschlusses des Deutschen Bundestages gefördert.

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The research project is investigating highly dynamic edge AI systems that can significantly increase the resource efficiency of production technologies via integrated in-situ process controls. The model process of precision spark erosion will be used to investigate the extent to which highly dynamic edge AI systems can reduce the ineffective process states of idling and short-circuiting.
As a basis for process control, new fault-tolerant machine learning methods are being researched that enable predictive forecasting of process parameters. Novel machine learning methods are used which are generative and, above all, fault-tolerant. The new type of process control is then implemented and tested for precision spark erosion. An innovative element here is the highly dynamic design of an additional actuator system.

This project is supported by the state of Saxony-Anhalt with funds from the European Union as part of the European Regional Development Fund (ERDF).
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Additiv+ is a production laboratory with a high-tech character. The incubator has been continuously developed and expanded since 2016. Additiv+ was funded for two periods from 01.09.2016 to 31.08.2019 and from 01.09.2019 to 31.08.2022 by the state of Saxony-Anhalt (ego. incubator program). With the continuation and expansion of the Additive+ offer, OVGU would like to further optimize the existing process chains and use them more intensively in a targeted manner.

Thanks to the equipment available in the Additiv+ incubator, users are able to additively manufacture metallic components using an SLM system. The manufactured components can then be finished using grinding systems and evaluated with regard to surface topography and roughness using existing measurement technology. In additive manufacturing processes, components are created layer by layer from loose material, e.g. powder, liquids or solids (wire, filament, foils). This special manufacturing process results in a high degree of design freedom, which enables the creation of complex component geometries. This makes additive manufacturing suitable for the production of individualized prototypes, individual parts and even small series.

This project is supported by the state of Saxony-Anhalt with funds from the European Regional Development Fund (ERDF).
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As part of the joint project, a production and assembly process suitable for series production is to be developed that makes it possible to manufacture stator stacks from circular segments instead of circular rings using laser cutting and to package them into individual stator segments. The more effective use of materials leads to a significant increase in the number of units produced while simultaneously reducing costs. The OVGU's sub-project focuses on the multiphysics simulation of the structural-mechanical and electromagnetic properties and the development of an analysis tool for the resulting complex component geometries. The aim is to correctly map the influence of manufacturing tolerances within the various production steps on the overall product performance using multiphysics simulation.

This project is supported by the state of Saxony-Anhalt with funds from the European Union as part of the European Regional Development Fund (ERDF).
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The aim of the project is to develop a technology that enables 3D geometries and microstructures to be incorporated into cold impact cores made of hard metal materials by means of electrochemical ablation and to replace the process chain used to date. Previous research work has shown that the use of pulsed current in particular has a significantly greater effect on the ablation result with hard metals. Compared to the removal of conventional metals, this effect is highly non-linear and not scalable. For this reason, the project focuses on high-precision pulse currents in the range of 10 Hz to 60 Hz for the resource-efficient production of 3D geometries in cold impact cores.

This project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) on the basis of a decision by the German Bundestag.
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Due to the wide range of applications of EC ablation in automotive, aerospace, medical technology and tool and mold making, the processing station for EC precision ablation includes the necessary equipment with additional components that enable research into fundamental issues through to applied research along the product value chain. EC precision ablation is based on the ablation of metallic materials using pulsed direct current and an oscillating cathode. Due in particular to the process-related advantages, such as damage-free surfaces, high surface quality and burr-free machining, EC precision ablation is the focus for highly stressed components and precision components whose surfaces must not be affected by the manufacturing process. In addition to researching the basic material-specific removal mechanism of EC precision machining, research at the Chair of Production Engineering with a focus on cutting will focus on resource-efficient EC technologies, process control of EC precision machining through simulation as well as interfaces and data chains for digital twins of EC precision machining processes.

This device is funded by the German Research Foundation (DFG) with project number 467011871.
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Precision spark erosion is a machining process in precision and micro-manufacturing technology that is used to produce tools and machine elements with the highest precision requirements. Due in particular to the process-related advantages, such as machining independent of the mechanical workpiece properties and freedom from burrs, precision spark erosion is the focus for highly stressed components and products made of high-strength materials. Using the device applied for, the process variants of precision spark erosion sinking, precision spark erosion drilling and precision spark erosion milling can be researched. In addition to micro-manufacturing issues in the near-surface area, research work in the macroscopic component area focusing on precise shaping, resource-efficient production and functional surfaces can also be realized. The device applied for addresses components with processing areas of up to around 600 cm², which can be processed using a required pulse current of up to 80 A. In addition to researching the fundamental process understanding of precision spark erosion, the Chair of Production Engineering with a focus on cutting will also focus on resource-efficient technologies, process control of precision spark erosion through simulation as well as interfaces and data chains for digital twins of precision spark erosion.

This device is funded by the German Research Foundation (DFG) with project number 509924008.
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In machining production, surface integrity depends on many different, interdependent influencing factors such as cutting parameters, tool wear, process dynamics, etc. Monitoring these manufacturing processes using sensors and timely intervention in the event of unstable process conditions can help to maintain the process. However, conventional process monitoring quickly reaches its limits if, for example, there are few or no options for detecting any disturbance variables and identifying corresponding characteristics in the sensor signals. In the production of individual parts and small batches, for example, there is simply not enough time to collect and evaluate the relevant information. Artificial intelligence offers the possibility of overcoming the previous limitations in the field of process monitoring with regard to reliable feature recognition in machining.
This is where the DeepProMach research project comes in, in collaboration with partners in Hungary. The aim is to develop an intelligent device that can be integrated directly into a machine tool. It is designed to detect critical process conditions during production before they can cause damage. If an unstable condition is detected or predicted, appropriate action is to be taken, such as communicating with the machine control system to adjust the process parameters or notifying the machine tool operator.

This project is funded by the Federal Ministry of Education and Research.
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The main objective of the project is to reduce CO₂ emissions in secondary aluminum production while simultaneously increasing efficiency through the use of green hydrogen. This is to be achieved through the combined use of hydrogen to replace fossil natural gas and oxygen enrichment in the combustion air in a smelting furnace for the production of secondary aluminum, as both gases are produced during electrolysis for the production of green hydrogen. Various issues and aspects relating to the effects that occur must be examined in more detail and the corresponding compensation measures investigated and developed.

This project is funded by the Federal Ministry for Economic Affairs and Climate Protection on the basis of a decision by the German Bundestag.
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Diese VDE SPEC soll eine falschfarbliche Markierung von elektrischen Funktionen von Vorrichtungen für das elektrochemische Präzisionsabtragen festlegen. Die notwendigen falschfarblichen Markierungen werden definiert. Diese VDE SPEC soll ausschließlich für das elektrochemische Präzisionsabtragen mit gepulstem Strom und oszillierendem Arbeitsabstand gelten.

Dieses Projekt wird vom VDE Verband der Elektrotechnik Elektronik Informationstechnik e.V. gefördert.

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This DIN SPEC defines the term "AI testing tools" and specifies requirements for AI testing tools that are used to evaluate, for example, robustness, IT security, reliability and fairness.

This project is funded by the Ministry of Economic Affairs, Industry, Climate Protection and Energy of the State of North Rhine-Westphalia.
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In building services engineering, pipe and cable penetrations for electricity, water and gas lines in masonry are currently usually realized by core drilling. The pipe walls must be sealed to the masonry in a very stable and durable manner and must meet very high requirements. As part of the project, a 2-component adhesive, which is known for bonding glass panes and body parts in the automotive industry and in rail vehicle construction, is therefore to be used and modified for sealing annular spaces. This modified 2-component adhesive is to be applied to the air gaps between the protective tube and wall material using a new type of equipment system.

This project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) on the basis of a decision by the German Bundestag.
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The aim of the study is to determine the need for research in the field of finishing metallic, additively manufactured components using ablative manufacturing processes. To this end, relevant ablative manufacturing processes that are suitable for the finishing of AM components will first be researched. Next, current challenges and machining results are to be clearly summarized. This will be followed by a comparison of the relevant manufacturing processes and a summary of component requirements in a process matrix. In a further step, achievable surfaces and removal rates for an additively manufactured steel material and a fused metallurgical steel material will be experimentally determined and compared using the manufacturing processes of electrical discharge machining and electrochemical precision ablation. Finally, recommendations for future research work are derived from the results obtained.

This project is funded by the Forschungsvereinigung Antriebstechnik e.V. (Research Association for Drive Technology).
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The aim of the project is to investigate the structural damping of (precision) machine tools in their
frequency ranges relevant to operation and thus minimize production inaccuracies caused by vibrations, thereby increasing machine accuracy. In order to achieve this , a reaction resin-based concrete formulation is to be developed, which consists of aggregates in addition to a polymer matrix. The aim is to achieve a damping ratio of more than 50 % and a frequency-selective damping ratio of more than 80 %. It should also be possible to adjust other physical properties, such as stiffness and thermal conductivity, through the choice of aggregates. The core of the positioning and production unit to be developed as part of this project for the construction of the composite materials is a newly configured extruder with an aggregate magazine, which is to be used for the additive production of machine components with a volume of up to 1 m³ from a reaction resin system-based concrete. The positioning accuracy of the positioning and production unit with regard to depositing the aggregates is at least ±0.1 mm.

This project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) on the basis of a decision by the German Bundestag.
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The aim of the project is to develop a technology that makes it possible to detect critical environmental conditions for installed wooden windows and doors in order to prevent damage and avoid unjustified claims. The background to this is the frequently fluctuating and extreme conditions on construction sites in terms of temperature and humidity, which can result in irreparable structural and geometric changes to the timber elements. To this end, the complex relationship between the influencing parameters of temperature and humidity and the damage resulting from their progression over time is to be investigated. The aim is to integrate a specially developed sensor system into the wooden elements, which records, documents, evaluates and signals the environmental conditions when a critical state occurs.

This project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) on the basis of a decision by the German Bundestag.
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The aim of the effiKeD project is to research the efficient production of splined shafts with increased fatigue strength. Specifically, technical possibilities for increasing efficiency and for targeted modification of the component surface layer in the production of splined and gear shafts are to be researched. To achieve the objective, a process combination of machining and forming processes is being sought.

This project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) on the basis of a decision by the German Bundestag.
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The basic principle of all electrochemical (EC) machining processes is the anodic dissolution of a metallic workpiece at its interface with a liquid ion conductor, the electrolyte, under the influence of electrical charge transport. The ablation principle makes it possible to process metallic workpieces regardless of their mechanical properties. In addition, ablation is force-free and takes place at maximum process temperatures of approx. 80°C. Compared to competing cutting manufacturing processes such as milling, grinding, spark erosion or laser ablation, this enables the economical machining of complex geometries with damage-free surfaces. By combining a pulsed current with an oscillating working gap, the imaging accuracy of EC ablation can be increased to the single-digit micrometer range. This results in technological potentials of electrochemical precision ablation for gear geometries, which are to be determined as part of the project.

This project is funded by the Forschungsvereinigung Antriebstechnik e.V. (Research Association for Drive Technology).
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Aluminum is an indispensable and future-oriented material with countless areas of application, such as the transport and packaging industries as well as the construction sector and classic mechanical engineering. The overarching aim of the H2-Alu project is to reduce CO₂ emissions during the production of secondary aluminum and its processing using casting technology, while at the same time increasing the efficiency of the overall process. This will significantly advance the German government's climate targets and the achievement of CO₂ neutrality for all industrial sectors. The goals of the project are to be achieved through the combined use of green H₂ to replace fossil natural gas and O₂ enrichment in the combustion air in a smelting furnace for the production of secondary aluminum. The mutual affinity of H₂ and aluminum - the most important industrial non-ferrous metal in the world - and the associated effects on the quality (e.g. gas porosity) of the castings to be produced is generally known, but the exact alloy-specific effects have not yet been precisely clarified. Therefore, it is to be investigated whether the planned H₂-addition leads to an impairment of the melt and casting quality. The central questions include the analysis of the effects of H₂ on product quality and the development of compensation measures to maintain the actual quality as a minimum requirement. For this purpose, basic material science investigations of the influence on the product aluminum along a real production chain are to be carried out using comprehensive laboratory tests (metallography, computer tomography, hardness measurement, tensile test, melt gas extraction, etc.). A CFD simulation module to be developed will take into account the H₂ influence on the aluminum material when calculating the casting technology processes and predict the effects.

This project is funded by the Federal Ministry of Education and Research.
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The overall project objective is the development of an ECM technology and the realization of a suitable modular device for the integration of device modules for the processing of permanent magnets for electric drives.

This project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) on the basis of a decision by the German Bundestag.
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This DIN SPEC specifies requirements for the use and (internet-based) trade of polyamide-based plastic recyclates based on the methodology of DIN SPEC 91446. It is aimed at manufacturers and users of polyamide-based plastic recyclates as well as all value chain participants who trade in these materials or test the material properties.

This project is funded by the DIN German Institute for Standardization.
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This VDE SPEC is intended to specify requirements and boundary conditions for the resource-efficient creation of digital twins of process energy sources for electrochemical precision ablation and to define the experimental setup and process parameters. The necessary work steps for the ablation experiments and the derivation of the process input variables are described. This VDE SPEC is intended to apply exclusively to electrochemical precision ablation with pulsed current and oscillating working distance.

This project is sponsored by the VDE Association for Electrical, Electronic & Information Technologies.
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As part of the eleMentio2 project, a method for the atomistic description of new materials is to be developed for the resource-efficient determination of process input variables for electrochemical precision ablation. This will enable access to the elementary processes taking place at the atomic-microscopic level and a fundamental understanding of these processes.

This project is funded by the Federal Ministry of Economics and Climate Protection (BMWK) on the basis of a decision by the German Bundestag.
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The aim is to develop a new sensor-based tool and a new type of technology for machining highly stressed inner and outer surfaces of spherically shaped surfaces using the example of joint sockets. The aim is to achieve an almost uniformly structured spherical surface using newly developed tools and cutting geometries with innovative process control. This is achieved in a single work step (without reclamping). For this purpose, suitable tool concepts must be developed and production processes adapted for their use must be qualified. Complex component geometries and the use of high-strength, difficult-to-machine metallic materials must be taken into account. The research project favors a machining process that uses defined cutting edges on a turn-mill machining center to achieve a defined surface roughness similar to a polished surface. In addition to coated carbide modifications as a cutting material, tool cutting edges made of diamond (monocrystalline diamond (MKD), polycrystalline diamond (PCD) and coated versions) and cutting ceramics are innovative approaches.

This project is funded by the DAAD with funds from the Federal Ministry of Education and Research (BMBF).
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The reason for the research project is the widespread use of wet machining in gear hobbing in German gear manufacturing small and medium-sized enterprises (SMEs), which predominantly use single and small series production. The reason for this lies in the higher process reliability that is sometimes indispensable for SMEs compared to dry machining. However, productivity when using wet machining varies greatly among SMEs. Furthermore, there are hardly any current research results available for wet machining. It is therefore also not known where the limits of wet machining lie and how great the potential is for optimizing the use of cooling lubricants for machining with modern production technology. Preliminary work as part of the FVA project 744 I (IGF no. 18538 BG) showed that the use of different cooling lubricants (dry, oil-based, emulsion) in gear hobbing leads to a significant variation in performance.

Based on the findings from the previous KSS-Pot study, experiments with other tool substrates will be carried out in this study in order to improve the process stability during the machining of high-strength gear blanks Rm > 1100 N/mm². Furthermore, the findings are to be transferred to gear blanks with strengths of approx. Rm = 900 N/mm². In all experiments, the focus is on the comparison between the cooling lubricants.

This project is sponsored by the VDW - Forschungsinstitut e.V..
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Additiv+ is a high-tech manufacturing laboratory. The incubator has been established since 2016 and is currently funded by the state of Saxony-Anhalt (ego.-INKUBATOR program). With the seamless continuation and expansion of Additiv+ at the end of the current project period, the Faculty of Mechanical Engineering (FMB) at Otto von Guericke University Magdeburg (OVGU) would like to further optimize the existing process chains and use them more intensively in a targeted manner.

In this context, the material and technical bases created (see internet presentation, including the OVGU MakerLab booklet at https://www.tugz.ovgu.de/makerlabs-path-706.html) and the extensive knowledge and experience of target group use gained from the previous funding period will be proactively integrated.

"Additive +" serves several interrelated fields of activity, on the basis of which new, innovative technologies, processes and products can be established for the market and later marketed.

Plastic-based additive processes are already offered by other ego. incubators at Otto von Guericke University. However, the design of functional, metallic assemblies requires a fundamental rethink on the part of users, which is primarily reflected in the aspects of "production-oriented design" and "functional integration".
New materials can be developed and coordinated process strategies for the SLM process can be advanced on the basis of powdered starting materials using Additive+ technologies and systems. The provision of surface finishing equipment and optical measuring devices ensures continuous quality control. Based on this, specific properties of the manufactured assemblies can be defined and evaluated accordingly. In this context, new quality standards can also be implemented, which in turn complement the existing technologies of other or already installed incubators (FabLab, PM, IGT).

This project is supported by the state of Saxony-Anhalt with funds from the European Regional Development Fund (ERDF).
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Development of a new manufacturing process for the production of defined and load-specific surface and edge zone qualities on mechanical connections of hip endoprostheses - KonRoll

This project is funded by the Federal Ministry for Economic Affairs and Energy on the basis of a decision by the German Bundestag.
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The aim of the investigations is to combine the advantages of milling tools (high removal rate) with those of grinding tools (high surface quality). To this end, fundamental investigations are to be carried out into the feasibility of combining these different machining operations. A central objective is the development, production and testing of a sample tool for milling-grinding machining in dry and wet cutting, which achieves low surface roughness with high flatness in the machining result.
The following sub-goals are associated with this objective:

• Reduction of the manufacturing effort and production costs for the surface treatment of machine components made of aluminum, steel and cast iron by integrating a grinding operation during the milling process
.
• Reduction of energy consumption in production through the process combination of milling - grinding in one tool and saving of process steps,
• Qualification of a dry milling-grinding process to avoid environmentally critical process waste products,
• Determination and optimization of cutting and process conditions for cutter grinding by means of an adaptable and therefore highly flexible arrangement and adjustment of the individual tool cutting edges,
• Increased process stability thanks to flexible grinding inserts in the milling tool and
• Minimization of the effort required for axial run-out adjustment or the use of cost-intensive precision milling heads in production
.

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The reason for the research project is the widespread use of wet machining in gear hobbing in German gear manufacturing small and medium-sized enterprises (SMEs), which predominantly use single and small series production. The reason for this lies in the higher process reliability that is sometimes indispensable for SMEs compared to dry machining. However, productivity when using wet machining varies greatly among SMEs. Furthermore, there are hardly any current research results available for wet machining. It is therefore also not known where the limits of wet machining lie and how great the potential is for optimizing the use of cooling lubricants for machining with modern production technology. Preliminary work as part of the FVA project 744 I (IGF no. 18538 BG) showed that the use of different cooling lubricants (dry, oil-based, emulsion) in gear hobbing leads to a significant variation in performance behavior.

While the preliminary investigations were carried out on the case-hardening steel 20MnCr5 with a tensile strength of R_m ~ 530 N/mm², the transferability of these findings to the machining of higher-strength materials with a tensile strength of R_m ~ 1000 N/mm² is of interest from an industrial perspective, as the power density of gears is continuously increasing. In particular, the technological and economic potential of wet machining compared to dry machining will be in focus. In the impact tooth analogy test, different cooling lubricants are to be examined with different cutting parameters on the workpiece material 42CrMo4. The results obtained are to be compared with the results of the previous project in order to evaluate the influence of workpiece strength.

This project is sponsored by the VDW - Forschungsinstitut e.V..
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A new cutting material is available for hobs, which consists of a virtually carbon-free, precipitation-hardenable iron-cobalt-molybdenum alloy produced by powder metallurgy (Fe-Co-Mo). This cutting material has better physical properties than high performance high speed steel (PM-HSS). These consist mainly of a higher thermal conductivity and a higher hot hardness.
The aim of the project is to promote a broad industrial application of this cutting material in gear hobbing. The main objective is to determine the application limits of Fe-Co-Mo and, as the main objective, sensible cutting value recommendations (permissible chip removal thicknesses and recommended cutting speeds) for various application conditions. One research focus is the analysis of occurring wear mechanisms and the wear/chipping rate behavior as a function of the load conditions.
A comparison between Fe-Co-Mo, PM-HSS and carbide under dry machining conditions is to be carried out in order to classify Fe-Co-Mo in the range of cutting materials commonly used in gear hobbing.
Due to the potential of hobbing with Fe-Co-Mo (in particular resulting from the possibility of using higher cutting speeds than is customary in the industry when using PM-HSS), the relevant companies in the industry, especially SMEs, are very interested.
The project is largely based on wear test results from the impact tooth analogy test. These are supported by penetration and FE simulation results with regard to the load parameters and design. In particular, the potential of the new cutting material under different cutting conditions and the limits of use in comparison with carbide and HSS are being investigated. The database will be expanded to include special applications through various types of cutting tests.

This project is funded by the Federal Ministry for Economic Affairs and Energy on the basis of a resolution of the German Bundestag.
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The standard defines requirements for a method for the non-destructive determination of mechanical properties of additively manufactured plastic parts for manufacturers of 3D printed components.

This project is funded by the DIN German Institute for Standardization.
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The main objective of the project is to develop and identify optimal tools and machining processes for the production of medical acetabular cups with optimized wear behaviour. The basis for this is the development of a model of the material CoCrMo based on material technology studies. The model is used to simulate the process in advance, to select suitable cutting materials and to develop the tool geometry in a way that saves time and resources. Validation takes place in the turning process.
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The content of this research project is the optimization of carbide hobs for use at the highest cutting speeds. Optimization approaches include: grain refinement of the K carbide substrate (ultra-fine grain), the use of Group P substrates (Group K carbide cutting materials are currently the industry standard), the testing of protective chamfers to relieve the cutting edges of the hob cutter teeth and the investigation of the influence of the flute pitch of the hob cutter on wear behaviour. By specifically varying these influencing variables, the design of the carbide hobs is to be improved in terms of achieving higher tool life with progressive cutting values.
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Chip formation during dry hobbing is simulated experimentally and by using the FE method. The results are Temperature input into the workpiece, distortion and its compensation possibilities.
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