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Simulation and Process Design

The RG Simulation and Process Design focuses on the simulation-based analysis and optimisation of NC machining processes with defined and undefined cutting edges (Fig.).


Basic investigations, e.g. the machining of hardened high-speed steel, are complemented by the development of innovative processes for structuring freeform surfaces using milling and grinding processes as well as the analysis of additive and subtractive process chains.

In cooperation with the RG “Virtual Machining” at the Chair of Software Engineering, one of the main research topics is the development of process simulation systems for the analysis and optimisation of machining processes. Regarding for example the simultaneous multi-axis micro- and macro­machining of complex structures, e.g. for the mould and die production or the aircraft industry, a simulation system for the analysis of the changing engagement conditions during the NC milling of complex free formed surfaces and the resulting effects is developed. For instance, the loads on the milling tool, complex vibration effects, thermomechanical deformations, and tool wear are investigated in various research works. The modelling and analysis of regenerative vibrations resulting from the interaction of the machining process and the dynamic behaviour of the tool-workpiece-machine-system is one of the main research areas. In addition to the milling simulation, models for grinding and honing are developed to predict the resulting surface topographies.

In conclusion, the potential of process simulations, whose application area comprises detailed analysis of the machining process at the cutting edge, the design of fixture systems and machine tool concepts, and the utilisation during the factory planning process, is investigated in different projects of funda­mental research and industry-related cooperation.


Komplexes Bauteil mit Werkzeug im Eingriff als Teaser © Breuckmann Frästechnik GmbH

Development of a process chain accelerated manufacturing process for the production of die-cast mold inserts based on a simulation-based methodology and resource-efficient recycling approaches


Fundamental investigations on the effect of structured functional surfaces of milling tools regarding process dynamics


Effects and interactions for interface and cutting-edge conditioning in hard mircomachining


Process Parameter Correlated Characterisation of the Corrosion Fatigue Behaviour of Post-Treated ZnAl-Coated Arc-Sprayed Systems


Modelling of the Axis Position-Dependent Process Dynamics for the Simulation-Based Optimisation of the NC Milling of Freeform Surfaces


Functionalisation of Tool Topographies for Material Flow Control and Tool Life Optimisation (CRC/TCRC 73 SP T07)


Simulation-Based Design of High-Performance Internal Grinding Processes

Abgebildete mirkoskopische Oberfläche als TEaserbild © ISF

Fundamental investigations on stabilizing damping effects in milling processes by using functionally structured peripheral cutting edges


Biologized Clamping Technology (BioClamp)

Hochgeschwindigkeitsflammspritzen von WC-Partikeln in Metallmatrix / Mikrostrukturierung der Schicht durch Mikrofräsen © ISF ​/​ LWT

CoatingStruc – Innovative Hybrid Manufacturing P rocess of Textured, Thermally Sprayed Surface Systems to Improve Friction Coefficients by up to 10%


Fundamental investigations on disturbing the regenerative effect in milling processes through the targeted design of tools with asymmetric dynamic properties

Mikrofräser mit Zoom auf die die Hartmetallspäne als Teaser © ISF

Process and Tool Development for Micromilling of Cemented Carbides

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Location & approach

From A1

Take exit Kreuz Dortmund/Unna to merge onto A44 toward Dortmund, which changes into the B1. Exit Dortmund-Dorstfeld toward Universität (onward see map).

From A 45

Exit Dortmund-Eichlinghofen toward Universität (onward see map).

Alternatively, you can calculate the route here: Google Maps.


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”.

Site Map of TU Dort­mund Uni­ver­sity (Second Page in English).