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Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
Dipl.-Ing. Kristian Arntz
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Dipl.-Ing. Kristian Arntz

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  • 1. Micro milling and laser ablation Two technologies complementing each other Dipl.-Ing. Kristian Arntz Fraunhofer IPT, Germany Aachen 22nd November 2011© WZL/Fraunhofer IPT
  • 2. Outline of the presentation  Overview of tool making activities at Fraunhofer IPT  Development of a platform for micro milling and laser ablation with the enabling technologies  Micro milling  Laser ablation  CAx-process chain  Demonstrator applications for Combined micro machining processes© WZL/Fraunhofer IPT Seite 1
  • 3. Process Technology at Fraunhofer IPT Fine Machining and Optics  Ultra-precision diamond machining, Precision grinding and polishing, Precision glass molding, FE process simulation, PVD coatings for tools and molds High Performance Cutting  Multi axial milling, Precision hard milling, Precision hard turning, Modelling and simulation of cutting processes Laser Machining  Laser beam joining and structuring, Laser-assisted machining, Laser surface treatment, Generative assembly manufacturing, Biotechnology CAx Technologies  CAx Framework, Development of CAM modules, NC simulation, NC data optization© WZL/Fraunhofer IPT Seite 2
  • 4. Laser Materials ProcessingSome of our Highlights Design structures Laser surface treatment Laser beam brazing Laser assisted turning Laser deposition welding Laser assisted metal spinning Welding of heat exchangers Laser deburring Structures for tribology© WZL/Fraunhofer IPT Seite 3
  • 5. The Tool Manufacturing Academy offers research, consulting andqualification with leading tool manufacturing companies Werkzeugbau Akademie Research and Development Industrial Consulting Qualification  Processing key aspects based on a  Bilateral projects concerning technical  Modular qualification proposals for development- and research- roadmap and organizational issues non-graduates and graduates  Acquisition of public research funds  Concept development and project  Top-class orators from industry and realization science  Accomplishment of contract research Sample tool manufacturing with a whole process chain and the support of the institutes Continuous collaboration on future issues in the tool manufacturing industrySource: Summerer, Siebenwurst, Rathgeber© Werkzeugbau Akademie Page 4
  • 6. The increasing level of technology and engineering affords theindustrialization in the tool manufacture Increased Level of Increased Level of Technology Performance Industrialization Academization Focusing & Cooperation Overall Long-term Manufacturing Enlarged product equipment qualification efficiency technology quality rating Product standardization Process standardization Professional Investments Systematical use of Technology chains research knowledge SynchronizationSource: Audi AG; Deckel Maho Gildemeister; t-mobile;© Werkzeugbau Akademie Page 5
  • 7. Process chain- oriented competency areas in process technology Development/ Service/ Marketing/ Construction Acquistion Manufacturing Assembling Distribution 2,5D – 3D – Geometry (Surfaces-) Surface Finishing Pre-Processing Generation Functionalization High Performance Cutting (HPS) Clamping Systems Design Structures and Functions High Speed Cutting (HSC) Wear protection Hard milling/ Micromilling CAx - Technologies Material engineering / Metallography© WZL/Fraunhofer IPT Seite 6
  • 8. Laser beam structuring – an innovative process for surface structuringHow it started: The challenge of "surface decoration" Etching  High manual effort  Poor reproducibility  Limited material range© Eschmann Textures  Restricted flexibility related to the structure design Electroforming  High manual effort  Moderate reproducibility  Poor flexibility  No consistency of a (digital) data chain © Galvanoform  Limited material range A wider scope related to the structure design, the increase of the reproducibility and the reduction of the manual effort require innovative solutions for the surface texturing in the tool and die manufacturing!© WZL/Fraunhofer IPT Seite 7
  • 9. Laser beam structuring – an innovative process for surface structuring"Removal rate and surface quality" – process basics  Use of pulsed laser sources – Pico- and nanosecond laser  Ablation with ps-laser (1 picosecond = 10-12 sec) – Material removal by sublimation (multi-photon- absorption): "Cold" ablation process => no thermal conductionFraunhofer IPT – Nearly all materials are processable – Removal of a small material volume by a single laser pulse – No melt formation on the surface  Ablation with ns-laser (1 nanosecond = 10-9 sec) – Linear absorption – Predominantly melt ablation: Thermal process with melt formation – Limited range of processable materials – Removal of a large material volume by single laser pulse – Low-cost laser sources© WZL/Fraunhofer IPT Seite 8
  • 10. Laser beam structuring – an innovative process for surface structuringApplication example "injection mold" – free formed surface Work piece specification  Injection mold  Basis material 1.2343 (X38CrMoV5-1)  Quenched and tempered to 50 +2 HRC  Laser structured area: Fraunhofer IPT 196 mm x 152 mm Result  Large-scale and seamless surfaceFraunhofer IPT structuring – Leather-grain K3A of the Volkswagen Golf VI Fraunhofer IPT – Hybrid-structure with micro- and macro structures – Geometrically defined pyramid Fraunhofer IPT structures© WZL/Fraunhofer IPT Seite 9
  • 11. The Integ-μ projectDeveloping integrated solutions for micro manufacturing  Platform 1b, led by Fraunhofer IPT, Germany Research partners  IPT, WZL/RWTH, KU LEUVEN Industrial partners  KERN, KISTLER, SWATCH, TWT, MT, LASAG Objectives  Development of an integrated machine tool system for a combined process of micro milling and laser ablation  System programmable through an adapted CAx-platform Integ-μ Project structure  Special monitoring systems to provide high reliability in micro milling© WZL/Fraunhofer IPT Seite 11
  • 12. Integ-μ Platform 1bMicro milling & laser ablation Targeted performance  multiple machining operations in one workholding configuration  processes will be used to complement each other (feature size, material, time)  stable micro milling process with tool steels > 55 HRC  laser structuring of freeform surfaces with very small feature sizes (12 μm focus diameter)  broad range of applicable materials Applications and market sectors Integ-μ Project structure  Flexible and cost-effective fabrication of micro moulds and micro parts Novelty and impact on EU industry  Fabrication of high precision complex 3D shapes with  increased flexibility, better accuracy, increased productivity, faster throughput, advanced materials and reduced handling and plant area© WZL/Fraunhofer IPT Seite 12
  • 13. Integ-μ Platform 1bMachine tool system for micro milling KERN PyramidNano  Travel X/Y/Z 500/500/400 mm³  Clamping area max. 600 x 600 mm²  Drives and guideways hydrostatic  Workpiece weight max. 250 kg  Feed rate 0.01 - 30,000 mm/min  Acceleration 10 m/s² (1g)  Rotational 360° continuous  Swivelling -20° up to +110°  Precision < 1μm  Weight approx. 8,000 kgSource: KERN Force measurement system for micro milling  Developed by WZL/RWTH and KISTLER© WZL/Fraunhofer IPT Seite 13
  • 14. Integ-μ Platform 1bMachine tool system for micro laser ablation KERN EVO  Travel X/Y/Z 300/280/250 mm³  Clamping area max. 350 x 230 mm²  Workpiece weight max. (3-axis) 50 kg  Rotational 360° continuous  Swivelling -10° up to +100°  Precision < 3μm  Weight approx. 3,000 kg Laser system Lumera SuperRapid  Wavelength 1064 nm / 532 nm  Repetition rate 80 to 1,000 kHz (200 kHz optimized)  Pulse width 10 ps  Average output power 17 W / 10W  Spatial Mode TEM00 (M² <1.3)Source: Fraunhofer IPT Scanner system Scanlab RTC5  Scanlab IntelliScan10 & VarioScan20i© WZL/Fraunhofer IPT Seite 14
  • 15. Integ-μ Platform 1bMachine tool system for micro laser ablation – Integration concept  Mounting plate with scanner, beam expander and mirrors in place of spindle  Laser source in place of tool changer  Laser provides two wavelengths at two separate outputs, so two beams had to be aligned on one path  Laser control unit  Separate industrial PC  Connected to machine control  Laser safety  Laser-safety windows  External clearance  Interlock (connected to machine doors)  Emergency shut-offSource: Fraunhofer IPT (Machine & laser source)© WZL/Fraunhofer IPT Seite 15
  • 16. Integ-μ Platform 1bLaser ablation – process development with first demonstratorsLaser ablation Several demonstration parts have Tool steel been realized Generation of data sheets and Copper storage of process data into "laser tools“ 10 mm Steel Cooper Graphite Source: Fraunhofer IPT (1.2343) R 8500 5 mm Average laser 6 7 7 Source: Fraunhofer IPT power [W] Graphite Pulse repetition 80 80 80 rate [kHz] Feed speed 300 300 500 [mm/s] Wavelength of 532 532 532 radiation [nm] 7 mm Source: Fraunhofer IPT© WZL/Fraunhofer IPT Seite 16
  • 17. Integ-μ Platform 1bThe software connection: Development of the CAx platform Complete digital process chain  Specialized CAM module for laser ablation  Basic and advances strategies for toolpath planning for the laser ablation process  Seamless integration in NX5 (by using the “CAx framework”)  Stand-alone version possible  Technology and process database  Virtual lasertools  Simulation tools availableIntegrated CAM module for laser ablation  Postprocessor  Laser control software “FlexOStruk”© WZL/Fraunhofer IPT Seite 17
  • 18. Integ-μ Platform 1bThe software connection: Development of the CAx platform Machine simulation  Simulation of Machine toolpath  Collision detection  Machine kinematics (linkage, offset) is stored in technology and process database  Machine simulation tool can be embedded into host system (NX) with use of CAx frameworkMachine simulation (KERN Evo with laser integration)© WZL/Fraunhofer IPT Seite 18
  • 19. Integ-μ Platform 1bCombined process – test pattern and expected benefit process issue benefit a) micro milling b) laser ablation sharpness of corners high material removal rate a b a weld penetrations (bottom) sharp corners b weld penetrations (lateral) sharp corners with high material removal rate a + b (+a) (and higher surface quality by finishig step) (high material removal (a+) b + a - rate with) sharp corners and higher surface quality© WZL/Fraunhofer IPT Seite 19
  • 20. Integ-μ Platform 1bCombined process – sharp corners© WZL/Fraunhofer IPT Seite 20
  • 21. Integ-μ Platform 1bDemonstrator part by Swatchgroup: Watch plate Source: Swatchgroup© WZL/Fraunhofer IPT Seite 21
  • 22. Integ-μ Platform 1bDemonstrator part: Decorative structures with Aachen Cathedral© WZL/Fraunhofer IPT Seite 22
  • 23. Integ-μ Platform 1bDemonstrator part: Decorative structures with Aachen Cathedral Source: Wikipedia  Decorative pattern  La Perlage / Pearl Pattern© WZL/Fraunhofer IPT Seite 23
  • 24. Integ-μ Platform 1bDemonstrator part: Decorative structures with Aachen Cathedral  Pocket (l,w,h): 7 x 1.8 x 2.3 mm³  Slice (l,w,h): 6 x 0.6 x 0.08 mm³© WZL/Fraunhofer IPT Seite 24
  • 25. Integ-μ Platform 1bDemonstrator part: Decorative structures with Aachen Cathedral  Control of form, chamfer and burr  Control of small radius  Control of burr© WZL/Fraunhofer IPT Seite 25
  • 26. Micro milling and laser ablation – complementary technologiesOutlook and vision Combining powerful micro fabrication technologies can contribute to  reduced processing time by developing intelligent machining and processing strategies  New functionalities by realising adapted and highly sophisticated surface properties  increased quality by realising special features and locally adapted properties The integration of laser systems in machine tools contributes to  the design of continous process chains including preliminary work and finishing  Specific setting of local material properties by automatically combining different manufacturing processes  Integrated CAx solutions which are able to represent and control whole process chains© WZL/Fraunhofer IPT Seite 27
  • 27. Your contact to Fraunhofer IPT Dipl.-Ing. Kristian Arntz Head of department Laser Materials Processing Fraunhofer Institute for Production Technology IPT Steinbachstraße 17, 52074 Aachen Phone: +49 241 89 04-121 Mobile:+49 174 1902817 Fax: +49 241 89 04-6121 Mail: kristian.arntz@ipt.fraunhofer.de© WZL/Fraunhofer IPT Seite 28

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