Machining and Machine Tools Laboratory (LZW)

Tasks

Machining technology

  • Analysis and optimisation of the following methods:
    - Turning
    - Milling and HSC milling
    - Drilling, lubricated hole drilling
    - Honing
  • Measurement and interpretation of cutting forces during plain turning, drilling and milling
  • Machine measurement and vibration analysis
  • Carrying out roundness 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

Staff

Prof. Dr.-Ing. Ulrich Walter
Hochschule Esslingen
Fakultät Maschinenbau
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:

  1. Index, Esslingen
  2. Grob, Mindelheim
  3. EMAG, Salach
  4. Diato/Gehring, Ostfildern
  5. Lang Spanntechnik, Holzmaden
  6. Mahr Messtechnik, Esslingen
  7. Kistler Messtechnik, Sindelfingen
  8. Forkardt Spanntechnik, Reutlingen
  9. Schunk Spanntechnik, Lauffen am Neckar

Apply for summer semester 2021!

Application period for programmes starting in the summer semester 2021
Bachelor’s programmes: 1 December 2020 to 15 january 2021
Master’s programmes (German): 15 October 2020 to 15 January 2021
Applicants to our international programmes should please see the Graduate School website for deadlines

Apply now