Metal Forming and Machining Laboratory (LUZ)

Metal forming and laser technology

In the Metal Forming and Laser Technology Laboratory of the LUZ, practical experiments to accompany the lectures on production engineering, metal forming and laser material processing are carried out in the form of laboratory exercises, project work is supported, and Bachelor and Master theses are supervised.

The tasks are supported with simulations and cover the whole process chain from the design of shaped sheet metal parts via the production through to the jointing.

  • Sheet metal forming: deep-drawing, bending, stretch forming, tribology, cutting
  • Bulk deformation impact extrusion, compression, rolling
  • Laser material processing: laser cutting, welding, marking
  • Press technology: structure, press drives
  • Tool engineering: method development, design, prototype dies

 

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

Prof. Dr.-Ing. Ulrich Walter
Hochschule Esslingen
Fakultät Maschinenbau
Labor für Umform- und Zerspanungstechnik
Kanalstraße 33
73728 Esslingen am Neckar

Telefon: +49 (0)711-397-3282
Telefax: +49 (0)711-397-48 3282

weitere Ansprechpartner

Bereich Umform- und lasertechnik:

Laboringenieur:  Dipl.-Ing. (FH) Achim Herdtle

Bereich Zerspanungstechnik:

Laboringenieur:  Dipl.-Ing. (FH) Frank Hafner

Equipment for metal forming and laser technology

Presses

  • Servo press (CSP 100 automatic stamping press)
  • F = 1,000 kN, see photo
  • Hydraulic triple effect deep-drawing press
  • F = 1,000 kN
  • Hydraulic double effect deep-drawing press
  • F = 630 kN
  • Eccentric press F = 630 kN

Testing equipment

  • TruBend 7036 bending machine
  • Acquisition Forming Limit Curve FLC (under construction)
  • Roll hemming machine with Kuka robot, see photo
  • Strip drawing facility
  • Experimental roll stand

Deformability behaviour of sheet metals

-    Recording Forming Limit Curve, see figure

FEM simulation

Method development and simulation of metal forming processes with AutoForm R7, see photo

Laser systems

True LaserCell 3000 4 kW disc laser, see photo

TrueMark Station 5000 marking laser

Workshop equipment

  • Machine tools for toolmaking
  • Equipment to produce prototype dies from low melting-point metal alloys
  • Metrological equipment to measure and record forming processes

Equipment in the Machining Technology Laboratory

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 on metal forming and laser systems

1. Semester

  • Foundations of forming technology
  • Strain hardening
  • Deep-drawing, bending, cutting, impact extrusion

6. Semester (Practical application module metal forming/laser machining):

  • Simulation with AutoForm: Tutorials developed at Esslingen University of Applied Sciences to accompany the lectures on metal forming help you to learn how to operate the AutoForm FE program using concrete, real-life applications.
  • Rapid Prototyping: You develop the optimum size of the starting blank for a deep-drawn part. Every student produces a drawn part with the aid of a prototype tool cast from a low-melting point zinc alloy.
  • Press drives: Different press drives are compared in the Metal Forming Laboratory.
  • Laser technology: Learn how a laser can be used for machining materials.
  • Programming of laser cutting and bending systems: At Trumpf (Ditzingen), you will develop a 3D shaped sheet metal part and program the laser cutting and bending machine for this part. The component you have developed will then be fabricated.

Master RMM:

  • Efficient drives for metal forming presses: You gain direct experience of the advantages of the direct drive with a modern mechanical press with servo-drive.
  • Method development: With the aid of concrete case studies, you develop the process chains to produce shaped sheet metal parts. You use the AutoForm FE system to support you.

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 activities

The Metal Forming and Machining Technology 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.

Metal Forming and Laser Technology Laboratory

Here are several projects by way of example which are being undertaken in the Metal Forming and Laser Technology Laboratory:

Research activities and projects

  • Resource efficiency along the sheet metal forming process chain
  • Construction of prototype moulds from laser-joined metal sheets
  • Development of a testing device for cutting oils
  • Backspring during stamping of flat sheet metal parts
  • Reduction in the number of forming stages with roll hemming

 

Industrial partners for the Metal Forming and Laser Technology Laboratory

- Schuler AG, Göppingen
- Trumpf GmbH & Co. KG, Ditzingen
- AutoForm Engineering Deutschland GmbH
- Daimler AG, Sindelfingen
- Behr, Stuttgart
- IgeL (Ingenieurgesellschaft für Leichtbau), Schönaich
- KGW, Karlsruhe
- Testo, Lenzkirch

 

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

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