EMO 2013: Fraunhofer presents solutions for tomorrow's production

At the joint stand of the Fraunhofer-Gesellschaft (Hall 13, Stand A54), the focus lies on high-performance materials and coatings for the manufacture of modern tools, improved tool geometry and innovative machining processes. In addition, demonstrators are used to show how tools, machines and plants can be actively isolated from external shock and vibration in an efficient and relatively inexpensive manner.

Maximum flexibility, consistently high quality despite shortened production times and top precision in the micrometer range: At EMO 2013, the Fraunhofer Institutes FEP, IPT, IKTS, IWS and IWU are bringing together their research expertise in metal processing. There will be joint presentations of newly developed technological processes and materials that address the dominant design trends in mechanical and plant engineering.

Plasma processes clear the way for high-performance cutting tools

The Fraunhofer Institute for Electron Beam and Plasma Technology FEP has various exhibits in which it demonstrates its expertise in the development of multilayer PVD coatings for wear protection in high-performance tools. These coatings contribute to an increase in productivity and manufacturing precision especially in high-speed machining and micro-machining. A newly developed high-performance plasma source used for the pre-treatment of tools provides excellent layer adhesion. FEP is specialised in the continuous development of the pulse magnetron sputtering (PMS) coating processes, including the necessary hardware components. This enables the production of customised solutions and thus particularly effective coatings designed to customer requirements.

High-performance materials for the highest demands

Optimisation of tools in regard to materials: The Fraunhofer Institute for Ceramic Technologies and Systems IKTS specialises in the design and development of tools on the basis of high-performance materials such as cemented carbides, cermets ceramics and other hard and wear-resistant compound materials. Based on their versatile characteristics these materials are well suited to a wide variety of applications: from cutting and forming tools for metals or wood and stone working, Actual developments include indexable cutting inserts, solid carbide drills and milling cutters, stamping tools and saw blades. Visitors to the booth will learn the extraordinary characteristics of exhibited high-performance tools made from nanoscaled hardmetals and several ceramic materials including an extra-hard tungsten carbide ceramic. These materials are characterized by an outstanding combination of hardness and strength.

With the example of a demonstrator the damping of tool holders by means of piezo-ceramic sensors and actors is illustrated. Compared to mechanical damping this method is characterized by a higher flexibility.

Efficient machining processes for tool and turbomachine construction

The Fraunhofer-Institute for Production Technology IPT in Aachen is currently developing new, more efficient machining processes for operations involving materials which are difficult to cut, such as those frequently used in the manufacturing of turbomachines, tools and dies. These innovative processes reduce the high levels of load to which the cutting edges of the tool are subjected. Furthermore, they lower process-related component vibration, thus stabilizing processes. Consequently, the cutting tools and tool holders can be used longer before they need to be replaced – saving both time and cost. The Fraunhofer IPT analyses machining processes systematically on the basis of actual components supplied by oAir Zoom Vomero 14