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Objectives In addition to manufacturing micro components directly, the production of high precision, complex cavities and functional surfaces in micro and precision mold making is an important link in the process chain of mass producing micro and precision components. Compared to conventional cutting and ablating techniques (milling, grinding and laser ablating respectively), high precision mold production has decisive advantages in terms of applicability and profitability. Depending on the process method in use, high geometric complexities can be achieved and— regarding the material—high rates of flexibility guaranteed. Our aim is to develop a machine tool that permits a hybrid milling-laser process with a machine-integrated geometric control. Approach In close cooperation with four medium- sized companies, we attempt to develop a flexible production system for manufacturing micro components and structures. The core of this production system is a high precision milling machine. By providing high-dynamic machine-axles and fast controls we can carry out high-speed cutting (HSC) with micro-milling and -grinding tools. Thus the processing of heavy duty materials such as steel alloys with a hardness of up to 64 HRC becomes possible with an accuracy of ± 0,5 μm. By integrating process modules for laser processing and optical structure recognition, the applicability of the production system, compared to available micro chipping systems, can be enhanced in terms of the dimension of structures that are minimally achievable, in terms of processing tolerances and in terms of surface qualities. Research topics cover questions pertaining to machine design, manufacturing technology, driving components and control algorithms. Results will be implemented in proto-typical machining systems. Fraunhofer IPK focuses its contribution to this joined research effort on the numerical simulation of optimizing the machine structure. Funding The research project is funded by the German Federal Ministry of Education and Research BMBF. Contact: |
