The machining division represents a technologically oriented research focus at ISF. It deals with scientific questions concerning the development, design and optimisation of tools and processes in the field of machining processes with a geometrically defined cutting edge. The range of activities includes fundamental research and industrial research and development as well as contract research and technological consulting. The objective is to develop application-oriented solutions for challenges in production technology in cooperation with other research institutions and in direct collaboration with partners from industry.
In terms of content, the department focuses on conventional cutting processes with geometrically defined cutting edge, such as drilling, turning or milling, followed by special processes derived from these, such as deep hole drilling, reaming or threading. The main fields of activity are the development, application qualification and efficiency increase of processes and tools as well as the machining of special materials. In this field, current analyses focus on lightweight construction materials, titanium and nickel-based alloys, composites, graded materials, fibre-reinforced plastics, intermetallic compounds and steels that are challenging to machine. The transfer of research results into practice is often carried out based on component-specific machining tests.
In addition to increasing process understanding and productivity, the focus also is on environmentally friendly as well as resource- and energy-efficient design of machining operations. The performance of experimental work with the help of the institute's extensive mechanical and metrological equipment is supplemented by the use of modern modelling and simulation possibilities. Simulations using the finite element method and metallographic preparation are both used to characterise process-related component changes, to deepen the understanding of the process, and to derive causal relationships in the process environment. A further focus is the efficient use of cooling lubricants in production. In order to understand the interactions between machining process and fluid and, based on this, to discover potential for improvement, both methods of experimental fluid analysis and flow simulation (Computational Fluid Dynamics) are used. The topics of digitalisation, sensor integration and surface functionalisation are gaining increasing importance within this division of the ISF, especially in connection with the influence on the surface boundary zone and thus the lifetime of highly stressed components.
Working Group Machining of Innovative Steels
Holistic Development and Characterisation of an Efficient Manufacturing of Detachable Joints for Aluminium and Magnesium Lightweight Materials
Fundamental Investigations of Micro Single-Lip Deep Hole Drilling of Challenging Drilling Situations
Vibration Reduction during Turning and Milling of Lightweight Materials with Tool Holders Produced by Laser Beam Melting
Investigations on Optimisation of the Cutting Edge of Twist Drills for the Machining of the High Temperature Resistant Nickel-Base Alloy Inconel 718
Investigations on the Influence of Machining and Sulphur Content on the Fatigue Strength of the Quenched and Tempered Steel 42CrMo4+QT
Development of a Simulative Model for Analysis of the Effect of Cooling Lubricants in Deep Hole Drilling with Small Diameters with Respect to Chip Formation
Geometrically Defined Surface Structuring for the Form-Locked Bonding of Thermal Sprayed Coatings
Efficient Modelling of Chip Formation in Orthogonal Cutting Based on Isogeometric Analysis and Modern Methods for Material Characterisation
Process-Integrated Measuring and Control System for the Determination and Reliable Generation of Functionally Relevant Properties in Surface Edge Zones during BTA Deep Hole Drilling
Fundamental Investigations on the Frictional Contact in the Working Zone in Machining Processes
Modelling of the Cooling Lubricant Distribution during Single-Lip Deep Drilling with Consideration of Chip Transport by Means of CFD and SPH/DEM Simulation for Tool and Process Optimisation
Research and Development of a Mechatronic Tool System fort he Compensation of Straightness Deviation in BTA Deep Hole Drilling
Lightweight and vibration reduced hybrid FRP-metal drill tubes with structure-integrated sensor technology for BTA deep hole drilling processes
Restriction of the Chip Thickness Deviations for Stabilising the Chip Formation of High Strength Metals
SPP 2231 FluSimPro - Coupled mechanical and fluid dynamic simulation methods to realize efficient production processes
Simulation and optimisation of the coolant flow to reduce thermal tool load during discontinuous drilling of Inconel 718
Tool and Process Optimization for efficient Ejector Deep-Hole Drilling-Processes using Smoothed Particle Hydrodynamics (SPH)
SPP 2231 FLUSIMPRO: Fully coupled fluidstructure-contact simulations to understand the processes in the contact zones during lubricatedorthogonal cutting
Fundamental investigations on the development of a single-phase CO2-lubricant solution to support deep-hole drilling processes for difficult to cut materials by using a cryogenic CO2 snow-lubricant jet
Development and implementation of a concept for the use of a low temperature emulsion in the drilling of Inconel 718
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Location & approach
Arrival by Deutsche Bahn to Dortmund or Bochum central station.
From Dortmund central station, take the S1 city train in the direction of Düsseldorf to the "Dortmund Universität" station (7 minutes journey time).
From Bochum central station, take the S1 city train in the direction of Dortmund to the "Dortmund Universität" station (14 minutes journey time).
The city train runs regularly every 20 minutes in both directions. From the city train station, take the Skytrain (S-Universität stop) to the Campus Süd stop (1 stop, runs every 10 minutes).
From Dortmund Airport
By taxi to TU Dortmund University, Campus South (approx. 20 min and 30 €, see Map)
From Düsseldorf Airport
Take the city train S1 in the direction of Dortmund to the "Dortmund-Universität" station (approx. 60 min). From here, take the Skytrain in the direction of Campus South or Eichlinghofen (runs every 10 minutes and takes approx. 3 min.).
The H-Bahn is one of the hallmarks of TU Dortmund University. There are two stations on North Campus. One (“Dortmund Universität S”) is directly located at the suburban train stop, which connects the university directly with the city of Dortmund and the rest of the Ruhr Area. Also from this station, there are connections to the “Technologiepark” and (via South Campus) Eichlinghofen. The other station is located at the dining hall at North Campus and offers a direct connection to South Campus every five minutes.
The facilities of TU Dortmund University are spread over two campuses, the larger Campus North and the smaller Campus South. Additionally, some areas of the university are located in the adjacent “Technologiepark”.