Technology Sheets

Creating functionalities with laser texturing

Femtosecond lasers are ultra-fast pulsed lasers, which are used to remove material. The material is not heated, but immediately turns into a plasma. In addition, the technology is extremely suited for the very precise application of functionalities via textures.

What a mobile cobot can do in production

Our consortium partner, Sirris, was given the opportunity to make temporary use of a KMR iiwa with the aim to extensively test and explore the potential of a mobile cobot.

Cryogenic machining, also for soft(er) materials

Cryogenic cooling during machining stands for machining at very low temperatures. This has advantages both for tools made of heat-resistant materials, where the heat can be high during machining, and for the machining of softer materials, which will flow more easily during machining.

Cryogenic cooling: an overview

Almost 10 years after the introduction of cryogenic machining, a lot of research has been conducted on this technology, its application and pros and cons. However, despite the positive results, the step to the industry does not seem to be so obvious.

Environmental impact of cryogenic machining

Sometimes the question arises to what extent cryogenic cooling is environmentally-friendly, as the gases used are a consumable, unlike other refrigerants that can be reused. Cryogenic processing does have interesting environmental advantages.

Collaborative Robotics

Introduction

Industrial automation and robotics are nothing new within manufacturing. However, a new paradigm is emerging which blends manual and robotic activities.

Additive manufacturing vs conventional machining process for complex geometry parts

Conventional machining process like milling, drilling, rolling, forming and so on, are still the most common go-to manufacturing operations for medium to large volume production. Additive manufacturing (AM) has been disrupting the manufacturing environment in the past decade with new possibilities for customised small volume production. Optimised manufacturing, for example, is very difficult to achieve with conventional machining processes, whereas with the help of additive manufacturing, this is easy with relatively fewer tooling changes, and much less time involved with the manufacturing operation.

A new method for finishing 3D Near Net Shape components

‘Near Net Shape’ components (NNS) are products that are almost in their final or finished form, and just need some finishing work in order to come within the required specifications, such as dimensional precision and surface roughness. Removal technologies are still the most common processes used for making the final finish that leads to the functional product. Therefore tool path generation for controlling CNC machines is essential.

Epicycloidal milling is up to 20 % faster than trochoidal milling

Among the different working strategies for ‘high performance cutting’ (HPC), trochoidal milling is an efficient way of processing (difficult materials), and is one that also utilizes a longer cutting edge. In order to increase productivity even further, (i.e. reducing the cycle times) the materials and processes laboratory at University of Karlsruhe has developed another strategy for trochoidal cutting, namely epicycloidal cutting.

Predictive Maintenance

End-to-end digitisation of physical assets within a value chain and their integration into a digital ecosystem is the focus of the fourth industrial revolution [1]. Ubiquitous sensors and microprocessors installed on machines, embedded systems and smart devices along with the increasing horizontal and vertical networking of value chains will result in unprecedently seen amounts of data.

Robot significantly reduces production time of large moulds

The arrival of machine hammer peening opens the way to fast finishing of large milled injection and deep drawing moulds. Instead of manual polishing, an industrial robot does the work in a shorter time. This process also offers a number of other advantages.

Machining electrically conductive ceramics with spark erosion (EDM)

Because of their extreme hardness, ceramic materials and their composites are very popular for mechanical applications that are susceptible to wear and tear due to heavy loads. The other side of the coin is that conventional techniques do not usually suffice to work these materials. Some are even impossible to grind, because oxides deposit on the grinding wheel.