InnoFert – Innovative Manufacturing Process Chain for the Production of ball nose milling cutters

PcBN ball nose milling cutters represent high-performance tools for the precise machining of complex geometries; however, their production remains associated with considerable time and resource requirements. Furthermore, there is a lack of industrially validated processes for the controlled formation of cutting-edge microgeometry – a key factor influencing tool life and component quality. Previous research projects on grinding and laser-based machining of PcBN have yielded fundamental insights into both process technologies. Building upon these findings, the proposed transfer project aims to promote targeted knowledge transfer to enhance the economic efficiency of tool manufacturing and to increase the performance and reliability of PcBN tools in industrial applications.

Objectives

The project aims to develop an industry-viable process chain for the manufacturing of high-performance PcBN ball nose milling cutters.

Practical relevance and expected benefits:

• Enhancement of the performance and efficiency of applied grinding processes
• Establishment of reproducible and controllable cutting-edge microgeometries
• Transfer of scientific findings into industrial manufacturing processes
• Contribution to resource efficiency and sustainability in tool production

Benefits

• Enhanced tool life and improved process stability
• Reduction of manufacturing effort and associated costs
• Reproducible and controllable cutting-edge microgeometry
• Improved surface and subsurface properties of machined components

Approach

The project builds upon findings from previous research on grinding and laser-based technologies. Within coordinated work packages, optimized grinding strategies and efficient laser processes are initially developed and subsequently integrated into a continuous, industry-applicable process chain for the production of PcBN ball nose milling cutters.

Project partners:

• MAPAL Dr. Kress SE & Co. KG: Implementation of economically efficient manufacturing and laser-based cutting-edge preparation
• Volkswagen Group Components: Evaluation and validation of the tools under near-series industrial conditions

Are you also interested in a cooperation project?

Contact Mohamad Kraja via email at kraja@ifw.uni.hannover.de or by phone at +49 511 762 19074.