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Professorship for Machine Tools and Forming Technology
Machine Tools

Division Machine Tools

Characteristics/Properties, Optimisation, Energy Efficiency

Vision

Considering especially the user‘s requirements, we research for new methods to analyse and optimise the properties of machine tools.

  • User-oriented evaluation of production plants to identify efficiency potentials
  • Precise machine simulation by means of experimental identification of property parameters
  • Optimizing of selected machine components
  • Conquer of consideration boundaries with interdisciplinary cooperation

Main Areas of Academic Research

Application-oriented assessment of machine tools and their components

  • Simulation-based and experimental property determination and optimization (static, dynamic, thermal) to increase productivity and quality

Extension of structural principles

  • Process-dependent further development of machine concepts by implementing active components

Machine tools components

  • Basic research for innovative operating principles and further development of traditional structures of framework assemblies, main spindles and guidance systems

Energy consumption analysis of machines

  • Determination of energy consumption with a mobile and cost-efficient multi-channel measuring setup over variable time periods and different sampling rates

Risk and hazard assessments

  • Energetic consideration of the risk of novel manufacturing processes and identification of human error probabilities

Target Groups

In the frame of fundamental and applied research projects the scientific teaching and research division “Machine Tools” is the competent technology partner for commercial companies as well as public organisations. Our service contains the development of application-specific constructions, prototypes for new applications, consultant service for the selection and adoption of innovative machine tools. The scientific teaching includes numerous seminars as well as transdisciplinary student project works and master theses. Additionally, the potentials of machine tools are shown to a wide range of users by workshops, expert discussions and demonstration activities.

Dr.-Ing. Joachim Regel

Head of Division

+49 (0)371 531-38147
joachim.regel@...
2/M109

M.Sc. Adrian Albero Rojas

Research Associate

+49 (0)371 531-30097
adrian.albero-rojas@...
2/M106b

Dipl.-Ing. Jan Berthold

Research Associate

+49 (0)371 531-33938
jan.berthold@...
2/M106a

Dipl.-Ing. Michael Bräunig

Research Associate

+49 (0)371 531-32499
michael.braeunig@...
2/M107b

René Fritzsche

Technical Employee

+49 (0)371 531-39756
rene.fritzsche@...
2/E026a

Georg Matschewsky

Technical Employee

+49 (0)371 531-38322
georg.matschewsky@...
2/E026a

M.Sc. Patrick Puschmann

Research Associate

+49 (0)371 531-35916
patrick.puschmann@...
2/M106b

M.Sc. Marek Schmidt

Research Associate

+49 (0)371 531-35898
marek.schmidt@...
2/M107a

Dr.-Ing. Volker Wittstock

Research Associate

+49 (0)371 531-37822
volker.wittstock@...
2/M108

M.Sc. Yingying Zhang

Research Associate

+49 (0)371 531-31026
yingying.zhang@...
2/M107b

Service Offer

 

Investigation of static and dynamic behavior

  • Experimental and calculative modal analysis
  • Simulation of static stiffness and deformation
  • Weak point analysis to improve the construction
  • Movie:
  • Contact:
    Dipl.-Ing. Jan Berthold
    ,
    M.Sc. Adrian Albero Rojas
 

Thermal analysis

  • Calculation of the temperature and deformation field of assemblies and machines for compensation and corrective measures
  • CFD simulation to investigate the cooling effect of fluid flows
  • Experimental temperature and displacement measurement of assemblies and components (tactile, non-contact)
  • Sensitivity analysis for the demand-oriented use of thermal measures
  • Contact:
    Dr.-Ing. Joachim Regel
    ,
    Dipl.-Ing. Michael Bräunig
 

Energy efficiency

  • Energetic machine characterization for energy-sensitive planning of machining production processes
  • Calculation of the process time and prognosis of the energy consumption
  • Contact:
    Dr.-Ing. Joachim Regel
    ,
    Dr.-Ing. Volker Wittstock
 

Linear guides

  • Investigation of friction for different materials and surface pressure (determination of Stribeck curve and starting friction coefficient)
  • Investigation of the floating of hydrodynamic guides up to 100 m/min
  • Property determination of lubricating oils
  • Contact:
    M.Sc. Yingying Zhang
    ,
    Dr.-Ing. Volker Wittstock
 

Piezo integration

  • Direct integration of piezo modules into locally microstructured metallic structures for condition monitoring, structural health monitoring and energy harvesting state and structure monitoring
  • Production of piezoelectric semi-finished products for further processing into "active" structural components
  • Automated micro-assembly
  • Contact:
    M.Sc. Marek Schmidt
 

Increased safety

  • Support for risk and hazard assessments (on real and virtual machines)
  • Energetic consideration of hazards during the process integration of turning in milling machines and calculation of stability
  • Characteristics of human reliability
  • Contact:
    Dr.-Ing. Volker Wittstock
    ,
    M.Sc. Adrian Albero Rojas
    ,
    M.Sc. Patrick Puschmann
 

AMARETO – Saxon alliance for material- and resource-efficient technologies

  • Partners: TU Chemnitz, TU Dresden, TU Bergakademie Freiberg, Fraunhofer IWU
  • Goal of the subproject C1.2: Time variable simulation of the thermal machine structure
  • More information AMARETO: AMARETO
  • Contact:
    Dr.-Ing. Joachim Regel
  • Duration: 01.01.2017 - 30.09.2020
 

PT-PIESA – High-volume compatible production technologies for light-metal and fiber-composite based components with integrates piezo-sensors and actuators

  • Partners: TU Chemnitz, TU Dresden, FAU Erlangen-Nürnberg, Fraunhofer IWU, Fraunhofer IKTS, Bayerisches Laserzentrum GmbH
  • Goal: High-volume production of active structural components
  • More information PT-PIESA: PT-PIESA
  • Contact:
    M.Sc. Marek Schmidt
  • Duration: 01.07.2014 - 30.06.2018
 

SFB Transregio 96 – Thermo-energetic design of machine tools

  • Partners: TU Chemnitz, TU Dresden, RWTH Aachen, Fraunfofer IWU, Fraunhofer IPT
  • Goal of the subproject A01: model-based discription, compensation and correction of thermal deformation for tools and clamping devices
  • More information SFB Transregio 96 (DE): Transregio 96
  • Contact:
    Dipl.-Ing. Michael Bräunig
  • Duration: 01.07.2015 - 30.06.2019
 

HDF 100 – Reduction of friction in hydrodynamic guides with reduced tendency to overturn for high sliding speeds through optimal design of the guides surface

  • Goal: Reduction of friction in hydrodynamic guides for high sliding speeds through designing the guides surfaces
  • Contact:
    M.Sc. Yingying Zhang
  • Duration: 01.09.2016 - 31.08.2019
 

HSP 3 – Development of peripheral and components for an adaptronic main spindle

  • Partners: TU Chemnitz, Institut Chemnitzer Maschinen- und Anlagenbau e. V., Spindel- und Lagertechnik Frauenreuth GmbH
  • Goal: Investigation of the thermal behaviour of motor spindles
  • Contact:
    Dr.-Ing. Joachim Regel
    ,
    Dipl.-Ing. Michael Bräunig
  • Duration: 01.02.2016 - 31.01.2019
 

RisDre – Risk of released workpieces during the process integration of turning in milling machines using probabilistic calculation approaches

  • Partners:Verein Deutscher Werkzeugmaschinenfabriken e.V. (VDW), Starrag GmbH
  • Goal: Better understanding of the risk and objectification of the expected operator risk during vertical turning on milling machines
  • Contact:
    Dr.-Ing. Volker Wittstock
    ,
    M.Sc. Adrian Albero Rojas
    ,
    M.Sc. Patrick Puschmann
  • Duration: 01.12.2016 - 31.12.2018
 

Basic investigations of energy efficiency potentials in industrial companies

  • Status-analysis regarding processes, machines, infrastructure and building
  • Visualising of energy flows in different factory levels
  • Detailed analysis and evaluation of selected potentials
    • More efficient use of energy
    • Possibilities to substitute expansive energy sources
    • Secondary use of waste energy
  • Contact:
    Dr.-Ing. Volker Wittstock
 

eMes-Plan – Empiric machine-models for the energy-sensitive planning of cutting manufacturing processes

  • Partners: ARC Solutions GmbH
  • Funded by: Central Innovation Program for SME (ZIM) of the Federal Ministry for Economic Affairs
  • Contact:
    Dr.-Ing. Volker Wittstock
  • Duration: 2014 – 2016
 
 

Determination of required characteristics of joint structures for deriving of improved compensating algorithms

  • New method to measure component stifnesses when mounted
  • Identification of frictional forces in joints
  • Compensation of static deformations in parallel kinematic mechanisms
  • Contact:
    Dr.-Ing. Volker Wittstock
  • Duration: 2009 – 2010
  • Funded by: German Research Foundation (DFG)
 

Competence-cell based production networks

  • Description and flexibilisation of the competence profile of product development expertise cells
  • Development of an evaluation method for product development services
  • Researches for technical proposal preparation in the product development phase
  • Elaborations for the formation of clusters of excellence to create innovative products
  • Duration: 2007 – 2009
  • Funded by: German Research Foundation (DFG)
 

Application of machine systems and realisation of the process chain spin extrusion/cross rolling

  • DFG-Transfer Sector 50
  • Contact:
    Dr.-Ing. Volker Wittstock
  • Duration: 2004 – 2007
  • Funded by: German Research Foundation (DFG)
 

eniProd &ndash Energy-efficient product and process innovations in production engineering

  • Energy accounting and management in machine tools
  • Development methodology for energy-efficient machine tools
  • Energy-efficient structural principles: mobile machines, bionic machines, thermally robust machines
  • Adaptability and reconfigurability of machine tools
  • Direct work space measuring systems for machine tools
  • Concepts for secondary energy use in machine tools
  • Measurement and simulation of braking and reactive energy cycles in machine tools
  • Contact:
    Dr.-Ing. Volker Wittstock
  • More information: Homepage eniPROD
  • Duration: 2009 – 2014
  • Funded by: European Union and Free State of Saxony
 

Horizontal machining center StarragHeckert HEC 500 D XXL Conqueror

  • Control: Siemens SINUMERIK 840D
  • Main spindle: 200 Nm; 31 kW; 50 – 15.000 min-1
  • Traverse distance (X/Y/Z): 850/750/850 mm
  • Rapid traverse distance (X/Y/Z): 60 m/min
  • Acceleration (X/Y/Z): bis 1g
  • Pallet size: 2 x 500 mm x 500 mm
 

Vertical milling machine Heckert CS 800

  • Control: Heidenhain iTNC 530
  • Main spindle: 700 Nm; 17 kW; 20 - 3.150 min-1
  • Table size: 2.200 mm x 870 mm
 

Spin extrusion machine BDM 2000

  • In-house development of the professorship in context of the DFG Collaborative Research Centre 283 (1995 – 2004)
  • First spin extrusion of the world that is ready for use
  • Punch force: 2.200 kN
  • Role force axial: 100 kN; radial: 300 kN
  • Main spindle speed of rotation: 630 min-1; Spunch speed of rotation: 480 min-1
  • Main spindle torque: 3.000 Nm
  • Main drive: 125 kW
 

Test station for thermal tool deformation

  • Analysis and evaluation of thermal tool deformation
  • Investigation of cooling methods (full jet cooling, minimum quantity cooling, air cooling)
  • Development of solution strategies (compansation and correction) to reduce thermal tool errors
  • Investigation of tool clamping mechanisms (shrinking, hydraulic clamping, surface clamping) in terms of accuracy determining properties
  • numerous tactile and non-contact measuring technology for displacement and distance measurement as well as for detection of fluid flows
 

Demonstrator energy-efficient machine tool

Self-sufficient linear test station
  • Evaluation of different guide systems
  • Strategies for needs-based cooling concepts
  • Determination of thermal properties of high performance concrete
Mobile 5-axis parallel kinematics
  • Investigation of linking strategies
  • Verification of coordinate assignment procedures
  • Development of adapted machining strategies
 

Test station sliding guide

  • Investigation of friction for different materials and surface pressures
  • Recording of the Stribeck-curve
  • Investigation of the floating of hydrodynamic guides up to 100 m/min
  • Testing of different lubricating oils
  • Effect of lubrication methods (permanent or pulse lubrication)
 

Main drives



Motor spindels
  • Investigation of motor spindels up to 55 kW under process-oriented loads
  • Static and dynamic property analysis
  • Thermal investigation
  • Innovative bearing concepts with active magnetic bearings
Belts and chains
  • Acquisition of preload forcs, torque and speed of rotation
  • Torsional oscillations between drive and output
  • Non-contact measurement of transverse oscillations
 

Feed Drives / Control Systems




Sliding guides
  • Basis: flat grinding machine BLOHM Planomat HP
  • Sliding guide (V-flat) in x-axis: feed rate up to 40 m/min, acceleration up to 3 m/s²
  • hydrostatic theaded spindle in x-axis (alternative: ball screw)
Slinding lining tests
  • Sliding speed: up to 2 m/min
  • Saddle forces: up to 1.000 kg
Roller guides
  • Stiffness and attenuation measurement when installed
  • Property analysis of mineral cast beds
 

Micro-assembly

  • Precision-linear and rotary measuring stages with recurrent errors < 2µm
  • Camera system with resolution < 2µm/px
  • Modular gripper head with integrated tripod kinematic
  • Gripper principles: electrostatic, vacuum, adhesive
 

TESTit Clamping force measuring device


Picture: Testit Clamping force measurement device (Hainbuch)
  • Clamping force measurement for external clamping devices with round clamping surface or two opposite clamping surfaces
  • Clamping force measurement in chucks and collets, 3-jaw chucks, 2-jaw chucks, vises
  • Max. claming force measuring range: at 3 measuring points max. 225 kN, at 2 measuring points max. 150 kN
  • stationary and rotary use with max. speed 6000 min-1
  • Data transmission via Bluetooth
 

Electrical power and energy measurement




Präsisions-Leistungsanalysator Yokogawa WT 3000
  • YOKOGAWA WT3000 with current coverter up to 1.000V, 200A
  • NI PXI-System: 96 channels, sampling rate up to 2,5 MS/s, deifferent transducers and current clamps up to 1.000V, 1.000A
  • Stand-y power measurement, reactive power measurement, measurement of the system perturbation
  • Precise 3-phase power measurement and analysis; sampling rate: 200 kHz; minimum update rate: 50ms
Power meter HT PQA 824
  • Power measurement and network analysis
  • 3 phases including neutral conductor and protective conductor
  • Minimum update rate: 1 s
A/D-transducer
  • Measureing voltage ± 10 V, evaluation with NI LabVIEW
  • NI USB6259: total sampling rate 1,25 MHz, 16 differential channels
  • SNI PXI 1024Q with 2x PXI 6133: sampling rate 2MHz pro Kanal, 2x 8 differential channels;le
 

Vibration measurement


Picture above: Brüel&Kjaer
Picture below: LDS Group
  • FFT-frequency-analyser with 11 channels; sampling rate per channel: up to 65.536 Hz; measureing range: 160 dB
  • Triaxial-/uniaxial-/miniature-uniaxial-accerleration channels
  • Force sensors up to 4,2 kN
  • Impuls hammer
  • Elektrohydraulic exciter; force: up to 1,5 kN; frequency: up to 800 Hz
  • Elektromagnetic exciter; force: up to 1 kN; frequency: up to 5 kHz
  • Elektromagnetic exciter; force: up to 300 N; frequency: up to 10 kHz
  • Software for evaluation of experimental modal analysis, order analysis and forms of operational vibrations
 

Climate chamber

  • Dimension ⇒ climate chamber size (L x B x H): 11,1 m x 8,3 m x 4,5 m
  • Foundation block (L x B x H): 8,15 m x 5,10 m x 1,00 m
  • Adjustable temperature from 10° – 40°C
  • Relative air humidity from 10% – 90%
  • Supply air flow max. 20.000 m³/h
  • Temperature-stable measurement-leverage, temperature sensors, distance measurement
 

Thermography




Mobile thermal camera Vario InfraTec hr680
  • Detector format (640 x 480) infra-red pixels
  • Temperature range (-40° – 1200°C)
  • Thermal resolution at 30° < als 0,4 K
  • Integrated digital color video camera with 1,3 megapixels
  • Thermography software IRBIS professional 16-Bit
High-speed thermography system InfraTec ImageIR 3300 MCT
  • Precision telephoto lens 100 mm
  • Attachment macro lens CL f = 500 mm
  • Thermography software IRBIS 32-Bit
Thermography system InfraTec VarioCAM Head
  • Precision wide-angle lens f = 12,5 mm
  • Normal lens f = 25 mm
  • Sapphire window, optically polished
  • Thermography software IRBIS professional 16-Bit
 

Force and torque measurement


Picture: Kistler
  • Kistler 3-component-dynamometer
  • Kistler rotating 4-component-dynamometer RCD
 

Laser interferometry

  • Renishaw laser interferometer XL-80
  • Traverse speed up to 60 m/min
  • Traverse range up to 40 m ± 0,5 µm/m
  • Linear measurement accuracy at 0° up to 40° C
  • Laser interferometric displacement measurement
  • Optics for measuring positions, tilt angle, straightness, rectangularity and rotary axes
  • Environment compensation (air temperature, air pressure,air humidity)
 

Circularity test

  • Renishaw ballbar system QC10
  • Test radii: 50 – 300 mm
  • Resolution: 0,1 μm
  • Accuracy: ± 0,5 μm
 

Construktion and dimensioning

  • PTC Pro/ENGINEER
  • Autodesk Inventor
  • Solid Edge
  • PTC Mathcad
 

Simulation and optimisation

  • ANSYS
  • FEMtools
  • TOSCA
  • MATLAB/Simulink/SimMechanics/SimPowerSystems
  • PLECS
  • ITI SimulationX
 

Measurement and Evaluation

  • AMS Beam
  • PULSE LabShop
  • ME'ScopeVES
  • NI LabView
  • NI DIAdem
  • HBM QuantumX Messverstärker
  • Messsoftware Catman easyAP

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