Research in Metal Cutting

Machining – Precision Through Cutting Processes

Data-Driven Analysis for Stable and Efficient Machining

At the Institute for Production Engineering (IFT), the machining index is being further developed as a productivity indicator in order to make the quality and stability of machining processes measurable. With the help of high-frequency edge data during machining, process parameters can be recorded, analyzed, and used for improved production control.

In addition to continuous tool wear measurement and surface characterization of the machined components, we also document chip formation and the resulting chips. Linking this information creates comprehensive process documentation that allows conclusions to be drawn about tool life, surface quality, and process reliability.

Research Focus Areas:

• Development of the Machining Index as a quality indicator
• Real-time acquisition and analysis of edge data
• Tool wear measurement and lifetime determination
• Surface characterization after machining
• Documentation and interpretation of chip formation
• AI-based evaluation and optimization of process parameters

Equipment at the IFT

• Siemens Industrial Edge Device (Sinumerik Edge)
  • Application: Acquisition and analysis of process data directly at the machine tool
  • Special features: Real-time data processing and interfaces for AI-supported evaluation
• DMG MORI Ultrasonic Linear 30
  • High-precision 5-axis machining of hard and brittle materials such as ceramics, glass, and carbide
  • Machining range: 300 × 300 × 300 mm
  • Ultrasound-assisted machining for reduced cutting forces and improved surface quality; integrated measurement technology and tool monitoring
• Spinner TC 400
  • Universal CNC lathe for research and training purposes
  • Machining range: Turning diameter up to 400 mm
  • Flexible control for experimental process analyses; suitable for wear measurements, process monitoring, and tool tests
• Spinner U5-630
  • High-precision simultaneous 5-axis machining of complex geometries
  • Machining range: Ø 630 mm × 500 mm
  • Equipped with modern control system and measurement technology interfaces; ideal for research work on process stability, accuracy, and tool load
• GST research grinding machine
  • Research and optimization of grinding processes (e.g., flat, cylindrical, and non-circular grinding)
  • Integrated sensor technology for force, temperature, and vibration analysis during the grinding process
  • Modular design for test adaptations; ultrasonic-assisted grinding operation; suitable for precision tests in research and teaching