Sustainable Production of Rotationally Symmetrical Components: Approaches to Resource Saving on Tool and Workpiece

Sustainability is an increasingly important trend, giving great potential in industrial production to save resources and energy. This paper presents fundamental research results on the reduction of cutting-tool consumption and saving on workpiece-material. For the basis of a new wear model, explicit knowledge of the thermo-mechanical loads and relative speeds between the tribological partners is of central importance. Therefore, a special open tribometer will be used to parameterize a friction model depending on relative speeds. Both, uncoated and coated tools are used. To reduce experimental effort, numerical simulations serve as an efficient representation of the cutting process. As a novelty in the project’s further course, both the experimentally determined tool temperatures and the friction conditions will be recorded in dependence on the tool wear, complemented by synchronized digitized wear images for validation purposes. The second work focuses on burnishing as a post-processing method for additively manufactured components. Compared to conventional machining, material and energy is saved and the workpieces’ surface integrity is improved, potentially increasing the components’ lifetime. Experimental tests are extended by finite element simulations, enabling investigations at different scales: At a workpiece model size of several millimeters, residual stresses are to be predicted; at a micrometer range, the surface smoothing is mapped.