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F R A U N H O F E R I N s T I T U T E F O R P R O d U C T I O N T E C H N O l O g y I P T
Turning processes – new compacT process chains and combinaTions
High-precision hard turning & honing / High-precision
hard turning & polishing
For many applications, hard turning provides an interesting
alternative to grinding techniques. Advantages that are spe-
cific to the process, such as short set-up times, dry processing
capabilities and a high degree of flexibility, make hard turning
techniques relevant, not only for the conventional field of
individual products and small series production but also for
mass production applications.
Most machining is performed on hard and hardened steels
as well as cemented carbides. The range of products consists
of bearing components, pneumatic and hydraulic parts and
chip-free forming tools. By optimizing the process (in terms of
cutting material, process parameters, machining strategy) to
improve the results, it becomes possible to achieve accuracies
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).
The Fraunhofer IPT develops ideas and solut ions for new combinat ions and chains of processes involv ing
turning. By combining honing and pol ishing with hard turning, i t becomes poss ib le to apply the technol-
ogy in new ways to hard and hardened steels and cemented carbides to achieve opt ica l surfaces. When
high-performance turning is combined with 5-axis mi l l ing, i t becomes poss ib le to process even hard to
machine mater ia ls without a machine change.
The aim of our research is to produce components with better to lerances and surface qual i t ies in less
t ime. This i s achieved by integrat ing the aforementioned process combinat ions into one lathe, which a lso
makes i t poss ib le to machine the workpiece without the need for re-c lamping.
High-performance turning
Only materials like titanium alloys, titanium aluminides and
nickel-based alloys are used in the manufacture of compo-
nents for turbo-engine applications – all materials with low
thermal conductivity and high heat-resistance that are hard to
machine. Over the last few years, the Fraunhofer IPT has built
up outstanding expertise in the 5-axis milling of these materi-
als. The analysis and optimization of NC data are essential
here – including the continuous analysis of the kinematic and
dynamic properties of the machines and controls.
We transfer the available knowledge to the turning process
and optimize the combination of turning/5-axis milling for
the manufacture of turbo engine components. The ability to
process such components in just one machine also eliminates
long, unproductive periods due to machine changes.
advanTages of Turning process combinaTions
Our offer
In our approach to technology-oriented process design,
we combine technological knowledge and experience with
manufacturing-orientated technology assessment. We help
you to improve your production processes and process chains
in terms of technical and economic criteria.
Our range of services in the field of turning includes
• Processing trials
• Feasibility studies
• Technology development
• Process development, process design and process optimization
• Manufacture of prototypes and small sized batches
• Help for industrial-scale implementation
Sophisticated equipment in conjunction with comprehensive
measuring and analysis facilities and software tools enables
the Fraunhofer IPT to process and evaluate complex, high-
precision components made of almost any material:
• Hard and hardened steels
• Cemented carbides
• Titanium and titanium alloys
• Nickel-based alloys
• Non-ferrous metals
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.
Our machining equipment
Three high-precision hard turning lathes (Hembrug)
• Slantbed on natural granite base
• External electric and hydraulic supply unit
• Integrated temperature-controlled coolant supply
• Hydrostatic bearings for spindle and support
• Spindle run-out accuracy < 0.1 µm
• Repeatability accuracy < ± 0.1 µm/150 mm
• Positioning accuracy < 0.1 µm/150 mm
• Integrated honing device (Hembrug 50 CNC)
• Integrated polishing spindle (Hembrug 100 CNC)
Monforts Unicen 1000 Multiturn
• Swing
– above bed 1 000 mm
– above cross slide 800 mm
• Machinable length 1 500 mm
• Compound slide rest X, Z and Y axis
• Interpolating B-axis
• Head with holder for static and powered tools
• Tool magazine (chain magazine) for 34 tools
• High-pressure cooling at 350 bar
• Tool and part measurement system
• Main and opposed spindle
Fraunhofer Institute for
Production Technology IPT
Steinbachstrasse 17
52074 Aachen
Germany
Phone +49 241 8904-0
Fax +49 241 8904-198
www.ipt.fraunhofer.de
Contact
Dr.-Ing. Thomas Bergs
Phone +49 241 8904-105
Fax +49 241 8904-6105
Dipl.-Ing. Jens Helbig
Phone +49 241 8904-136
Fax +49 241 8904-6136