High performance cutting

The “High Performance Cutting” department develops technologies and application-oriented solutions for a wide range of machining tasks – particularly for simultaneous, multi-axis milling and for turning geometrically challenging components made of super-alloys, ultra-high-strength steel, lightweight or composite materials or customized materials.  

Typical fields of application include components for turbomachinery, aircraft manufacturing and toolmaking as well as medical engineering.

Extensive technological knowledge, distinct system expertise and our state-of-the-art machinery are the prerequisite for a target-oriented approach which ultimately ensures a successful conclusion of our multi-disciplinary research and development projects – starting from the basic principles of machining to the development and optimization of processes through to prototype manufacturing.

Our fields of research and consultancy

• Basic principles of machining and modelling
• Analyzing and assessing machining
• Machining process planning and optimization
• CAM planning and NC optimization
• Consultancy and prototype manufacturing

When aiming to apply cutting processes to machine challenging materials efficiently in order to manufacture products, it is essential to be able to understand and assess the underlying physical principles. The "High Performance Cutting" department at the Fraunhofer IPT even developed modelling tools, a range of specialist test rigs and powerful measuring equipment, allowing an in-depth analysis of machining processes. Our unique machining test rig enables us to machine cut any given material into one orthogonal cut by using any tool required. We deploy high-speed cameras, thermographic cameras, force plates and temperature sensors to obtain unique insights into the machining process. As a result, we can exploit the understanding of the principles underlying the processes in order to develop processes systematically and to ensure optimum design.

Our services

• Characterizing tools and coatings on a special-purpose test rig
• Characterizing innovative materials on a special-purpose test rig
• FE machining process modelling in terms of strength, temperature, chip formation etc.
• Dynamic modelling of machining processes in terms of their vibration behavior

As part of our drive to optimize complex machining processes systematically, we conduct experimental machining studies in order to analyze and assess the influence exerted by the most important process variables on your milling, turning or drilling processes. This also includes analysis and assessment of the relevant tools, the process control parameters and the cooling lubricant strategies pursued. In addition to this, we analyze and assess the process stability and machinability of new metallic and non-metallic materials. For this purpose, we have not only an ultra-modern machine park but also highly specialized measuring equipment, ranging from force plates through high-speed and thermographic cameras to high-resolution microscopes and surface measuring instruments.  

Our services

• Analyzing and assessing cutting capability of tools and coatings
• Analyzing and assessing machinability of materials (conventional and special-purpose materials)
• Analyzing and assessing process parameter variations and cooling lubricant strategies
• Analyzing and assessing process stability

As part of our drive to optimize complex machining processes systematically, we conduct experimental machining studies so that we can analyze and assess the influence exerted by the most important process variables on your milling, turning or drilling processes. This also includes the analysis and assessment of the relevant tools, the process control parameters and the cooling lubricant strategies pursued. In addition to this, we analyze and assess the process stability and machinability of new metallic and non-metallic materials. For this purpose, we are not only provided with a state-of-the-art machinery but also highly specialized measuring equipment, ranging from force plates through high-speed and thermographic cameras to high-resolution microscopes and surface measuring instruments.

Our services

• Selecting suitable tools and customized optimization
• Selecting suitable machining strategies and customized optimization
• Customized optimization of the process control parameters
• Optimizing stability and avoiding vibrations
• Developing customized clamping concepts

Nowadays, it is virtually impossible to control complex, multi-axis machining processes without appropriate computer support – such as "CAx-solutions" (computer-aided x). In the "High Performance Cutting" department, we therefore develop CAx solutions which facilitate swift, efficient and reliable execution of even the most complex machining processes. Our software modules developed in-house enable us to not only generate individual NC paths but also to use appropriate tools for machine- and process-related analysis, assessment and optimization. Integrated technology modules allow for the process layout to be automated to such a degree that the user no longer requires any process expertise. The further development of general and standardized CAx modules is just as essential to our portfolio as the development of new and customized CAx solutions for industry.

Our services

• Machine and process related analysis and assessment of existing NC paths
• Machine and process-related optimization of existing NC paths
• NC path planning and generation for new processes and products
• Developing individual CAM modules

Shorter product life cycles and increasingly demanding quality requirements coupled with growing cost pressure call for technologically coordinated and efficient production sequences. The Fraunhofer IPT analyzes particularly challenging machine-related questions and issues on behalf of their clients and collaborates with them to develop sustainable improvements in processes and technologies. Our support extends well beyond the introduction of new machining technologies, reviewing their technological suitability and analyzing their economic potential. We also accompany our clients as they implement the respective technology in their company. At our institute, we test new technologies on the basis of specific products and manufacture prototypes of highly specialized components ourselves.

Our services

• On-site consulting on all machining-related questions
• Assessing suitability for technological implementation and the economic potential of new machining technologies and processes
• Integrating new machining technologies and processes in situ
• Producing individual demonstration parts and prototypes