High performance cutting

Fraunhofer Institute for Production Technology

The "High performance cutting" department provides practical manufacturing solutions for components used in the production of turbo machines, aircraft and tools. The focus is on simultaneous multi-axis milling and the turning of geometrically complex components made from super alloys, highly strengthened steels and lightweight and composite materials. An extensive understanding of technology, strong systems competencies and a unique machine pool provide the basis for carrying out R&D projects in a comprehensive and targeted way – from the development and optimization of processes to technological advice and prototype production.

Topics covered by the department

Machinability and tool design

With the help of a unique cutting test bed, we systematically investigate the relevant cutting conditions for simultaneous 5-axis milling. This is backed up by quick and well-founded analyses of the cutting behavior of innovative tools and materials as well as the systematic design of related milling processes.

Process and system modeling

We use software-aided technology models to analyze dynamic structural mechanics and interrelated effects in the entire system, consisting of the tool holding fixture, the tool itself, the component and the component clamping. This enables us to develop suitable process stabilization strategies, e.g. for thin-walled components or dies with large overhangs.

Application: turbo machines

We design all the turning and 5-axis milling operations for the manufacture of individual blades, discs, BLISKs and radial compressors and turbines and apply path strategies which we have optimized. We also develop modified clamping concepts and work on-site with our clients on comprehensive process optimizations.

Application: tool-making

The focus lies on the comprehensive design of all processing operations involved in the hard or HSC milling of complex cavities and tool components. The spectrum ranges from micro dies to large surface deep drawing dies. We provide our clients with on-site support on all issues related to process design.

Application: lightweight components

Our processing strategies make it possible to achieve maximum material removal rates and produce structural components out of aluminum, titanium and composite materials. We incorporate aspects of internal stress behavior that are the result of previous forming processes or of undesired process-related damage to the surface layer.

Consultancy and prototype manufacture

Using our technological insight and many years of expertise, we work together with our clients to develop solutions to all matters related to process selection, design and assessment. This includes technology benchmarks, investment advice and prototype manufacture.