Research

Grinding Technology and Superfinishing

  • HEDG
  • Hard-to-machine materials
  • Microgrinding
  • Non-conventional machining and hybrid machining
  • Dry grinding
  • Modeling and evaluation of processes
  • Measuring technology and process monitoring

Cutting technology

  • HSC
  • Micromachining
  • Hard-to-machine materials
  • Non-conventional machining
  • Investigation of tool geometry
  • Sustainability and green manufacturing
  • Modeling and evaluation of processes

Laser Technology

  • Microstructuring
  • Conditioning of grinding tools
  • Functional surfaces
  • Hybrid machining
  • Additive production (SLS)

Research projects

Development of a new resin-bonded, textured CBN and synthetic diamond grinding wheel for dry grinding of carbide metals and high-speed steel

  • Funding organization: National Ministry of Business and Energy (BMWi), 01/2013 - 12/2014
    Funding programme: ZIM joint project
  • Partner: Bärhausen

The main aim of the project is to develop a highly efficient and reliable finishing process which makes it possible to custom-grind hard materials, in this case carbide metals and high-speed steel, using textured grinding wheels.

Through the texturing, the contact surfaces between the grinding tool and the workpiece is reduced, i.e. parts of the grinding granules and the grinding surface are removed before they are applied. The reduction of the contact surface and reduction of the dynamic cutting edge numbers leads to constant interruption of the contact, which in turn has a positive influence on the chip formation process.

Development of an energy and resource-saving coolant nozzle for use in flat and contoured grinding processes: Eco-Düse

  • Funding organization: German Federal Environmental Foundation (DBU), 2014-2015
  • Partner: Bärhausen

The aim of the project is to develop, design, test and build a prototype of an energy-saving coolant nozzle which can be flexibly deployed. Using a prototype which has already proven its effectiveness and efficiency, applications, which until now have been limited to surface grinding with simple, straight wheels, will be considerably expanded. The aim of the project is to develop a prototype of a coolant nozzle which can be used as universally as possible, and which offers significant savings in the amount of coolant and energy required.

Analysis of dry grinding of cylindrical components with textured grinding wheels

  • Funding organization:German Forschungsgemeinschaft (DFG), 2014-2015
    Funding programme: research grant

The aim of the project is the efficient realization of the dry grinding of cylindrical components using textured grinding wheels through a thorough analysis of the links between the design of the structure of the grinding wheel surface and energy consumption and distribution in the grinding contact zone, as well as detailed testing of the peripheral zone formation through the thermo-mechanical stresses related to the grinding conditions and macro- and microtopography of the grinding wheel.

High performance/high speed grinding of carbon-fibre reinforced ceramic materials using innovative tools and highly efficient emulsion - Hybrid Lightweight Construction

  • Funding organization: Baden-Württemberg Ministry of Science, Research and the Arts 2014-2017
    Funding programme: Baden-Württemberg joint research: fibre-reinforced materials
  • Partner: Riegger-Diamantwerkzeuge, HKS, HAUX Maschinenbau, Epucret

This project deals with the creation of a new, integrated technology for the  processing of hybrid lightweight construction materials using high-performance/high-speed grinding. Of prime importance is the development of innovative metal and hybrid-composite diamond grinding wheels which are highly efficient and process reliable, as well as the application of new grinding kinematics (see picture 1).  The development of a high-performance grinding machine with a filtration plant optimized for ultra-fine particles, a coolant lubricant suitable for the process, and an in-process laser-conditioning method (see picture 2), are also planned. The goal of the project is a reliable and high-performance finishing of hybrid materials, which will lead to environmentally friendly and cost-effective production and thus to a broader industrial application of hybrid lightweight products.

Development of a new generation of machines to dress diamond grinding wheels using lasers - LaserDress

  • Funding organization: Federal ministry for Economic Affairs and Energy (BMWi) (2014-2016)
    Funding programme: ZIM Joint research project
  • Partner: Kirner Maschinenbau

Grinding machines with diamond granules are often used for the finishing of brittle and hard materials (carbide metal, ceramics, glass). The tool life is economical thanks to the extreme hardness of diamond granules. However this advantage is also a large disadvantage: contouring and dressing is very time-consuming. The silicium-carbide dressing rolls which are used are liable to considerable wear and tear. Therefore this process will be replaced with a completely new process using a non-wearing laser which until now has not been available on the market. This introduction of a new generation of machines makes it possible for the first time, to use the whole process of conditioning of diamond grinding tools, non-wearing and with a high precision in a machine, and thus being able to take advantage of optimally designed macro- and micro topographies of the tool surfaces. Kirner Maschinenbau is responsible for the development of the innovative core of the new machines while the development of the processes is carried out by the Institute for Precision Machining (KSF).

Innovative use of picosecond lasers in the dressing and texturing of CBN and diamond grinding tools

  • Funding organization: Baden-Württemberg Ministry of Science, Research and the Arts
  • Funding programme: Innovative Projects / Joint project in BW universities
  • Partner: Bärhausen, Trumpf

High temperatures are the outcome of grinding processes. Solid cooling lubricants are used to reduce or dissipate the unwanted heat in the contact zone and small amounts of these end up in the grinding zone. The creation of special structures on grinding wheels is an effective way to reduce the temperature in the grinding wheel-workpiece contact zone.

The laser method is used due to the high precision and the possibility to produce complex and narrow structures. The use of a picosecond laser offers the advantage of very short processing times and thus optimal control of the process. In this way a selective finishing of the various materials of the composite and the granules is made possible. Additionally, the use of a laser avoids the high consumption of cooling lubricant, considerably reducing environmental pollution.

Teaching

Lectures and courses offered by Prof. Dr. Azarhoushang:

Courses:

  • Production engineering I & II
  • Machine tools
  • Precision machining techniques
  • Production measurement technology
  • Fundamentals of technical mechanics II
  • Materials mechanics
  • Precision Manufacturing

Lectures are offered in the following areas:

  • vDD - The future of dressing in ceramic compounds?
  • Tools, machines and processes in ultra-precision grinding
  • Surface grinding with lap kinematics and continuous flat film extrusion feed - Fine Grinder
  • The intelligent mineral cast bed - an adaptronic approach to avoiding thermal-related deformation in machine frames
  • Sand and shot blasting
  • Limitations of precision machining. High precision machine concepts for microgrinding, micromilling and microlasering