Machining and Machine Tools Laboratory (LZW)
Staff
Prof. Dr.-Ing. Ulrich Walter
Hochschule Esslingen
Fakultät Maschinen und Systeme
Labor für Zerspanungstechnik und Werkzeugmaschinen
Kanalstraße 33
73728 Esslingen am Neckar
Telefon: +49 (0)711-397-3282
Telefax: +49 (0)711-397-48 3282
weitere Ansprechpartner
Laboringenieur: Dipl.-Ing. (FH) Frank Hafner
Equipment
Machines
- Index V160 CNC vertical milling machine for workpieces up to D=200 mm with automatic loading and discharging for turning, milling, drilling and thread cutting. Possibility to install additional tools (milling, grinding, honing spindle)
- Digma HSC 300 HSC milling machine with 3 axes, speeds up to 40,000 rpm, with CAD-CAM coupling
- Production CNC honing machine from Gehring for long-stroke honing, path and force controlled
- Several CNC milling machines, one 3-axis production milling machine, one 4-axis machining centre with 80 tools, one fast 3-axis machining centre
- One stable CNC plain lathe for workpieces with Dmax=400 mm and 1 m in length
- Grob G350 – 5-axis machining centre with pallet changer
Metrology and test equipment
- Kistler force measurement platform (3-axis) to measure forces and moments during milling, drilling, tapping, honing etc.
- Kistler force measurement platform (3-axis) to measure forces and moments during turning
- Various path, vibration, acceleration and temperature sensors to measure machine, tool, vibration and temperature characteristics
- Mahr roundness measurement device with a measuring resolution of 0.1 µm
- Tool calibration on modern tool calibration and setting device
- HBM measurement amplifier
- Temperature measurement equipment
- Piezo acceleration measurement equipment for vibration measurement
- Laser interferometry
- Olympus measuring microscope
Laboratory Exercises
Laboratory exercises in machining
- Analysis and optimisation of the following methods:
- Turning
- Milling and HSC milling
- Drilling, lubricated drilling
- Honing
- Measurement and interpretation of cutting forces during plain turning, drilling and milling
- Machine measurement and vibration analysis
- Roundness and cylindricity measurements
- Surface and profile measurements
- Dry machining
- Hard turning and milling
- Implementing CAM solutions for HSC milling (3, 4 and 5-axis)
- Testing and assessment of new tools and clamping devices
- Method development
Vibrations of machine tools
- Analysis and stability
- Measurement of dynamic stiffness
- Externally induced and self-induced vibrations
- Use of auxiliary tuned mass damper
- Use and understanding of metrology
Production and measurement of workpieces
- Self-contained production of a workpiece on various machine tools (conventional lathe, CNC lathe, CNC 5-axis machining centre)
- Measurement of the workpieces produced with different production measuring machines (roundness, surface measurement machines, manual measurement equipment)
- Analysis of results, also static investigations, and interpretation
Acceptance tests for machine tools
- Measurement of contouring errors with cross-grid encoders
- Calibration of NC axes with a laser interferometer
- Assessment of positional uncertainty
Clamping systems
- Use of clamping cylinders, clamping devices and zero-point clamping systems
- Shaft clamping technology
- Measurement of the positional uncertainty of a zero-point clamping system
Research and knowledge transfer
Research activities
The Machining an Machine Tools Laboratory headed by Prof. Dr. Walter collaborates closely with industrial companies in Baden-Württemberg. Medium-sized and small companies are often looking for support with process engineering issues. They in particular require simple and low-cost solutions.
Machining and Machine Tools Laboratory
Projects which were carried out in the Machining and Machine Tools Laboratory are listed below by way of example:
Research activities and projects
- Development of energy- and resource-efficient machine tools
- Cutting force measurements during turning, milling, drilling
- Investigations of the processes during hard turning and milling
- Development of a tool pressing-off fixture for milling machines
- Development of a lathe conversion kit for milling machines
- Temperature measurements in drilling experiments
- Industry 4.0 – CAD-CAM production
- Cutting data analyses for trochoidal milling
- Comparative analyses of different milling strategies
- Vibration analyses with machine tools
- Resonant frequency determination on machine tools
- Investigations of hones
- Cutting value determinations for honing
Industrial partners for the machining technology:
- Index, Esslingen
- Grob, Mindelheim
- EMAG, Salach
- Diato/Gehring, Ostfildern
- Lang Spanntechnik, Holzmaden
- Mahr Messtechnik, Esslingen
- Kistler Messtechnik, Sindelfingen
- Forkardt Spanntechnik, Reutlingen
- Schunk Spanntechnik, Lauffen am Neckar