Leibniz Universität Hannover Faculty Faculty of Mechanical Engineering
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Institute of Production Engineering and Machine Tools
 
Institute of Production Engineering and Machine Tools Research
Current projects

Current projects at the IFW

  • SenSGlatt - Increasing the technical availability of skived and roller burnished pipe products using a sensory tool for combined skiving and roller burnishing
    Combined skiving and roller burnishing is a process for manufacturing close-tolerance cylinder tubes for use as pneumatic or hydraulic actuator cylinders. The potential of combined skiving and roller burnishing remains largely untapped at present due to complex process setup and time-consuming quality controls. In order to reduce the high non-productive times, the Institute for Manufacturing Technology and Machine Tools (IFW) in Hanover is collaborating with Ecoroll AG Werkzeugtechnik on the “SenSGlatt” project to develop and research a sensory tool for combined skiving and roller burnishing. Based on process-parallel diameter detection and rolling force measurement, process data-based quality control over the entire bore depth and force-based process monitoring are being implemented for the first time.
    Team: Vornkahl, Jannes
    Year: 2025
    Funding: ZIM
    Duration: 02/2025 - 05/2027
  • Fatigue Strength Optimisation of Additively Manufactured Aluminium Components
    Additive manufacturing using Direct Energy Deposition-Arc offers great design freedom and high deposition rates, but also presents challenges. Aluminium components produced with this process often show inhomogeneities and porosities, which require post-processing. In a project funded by the German Research Foundation (DFG), the Institute of Production Engineering and Machine Tools (IFW) at Leibniz University Hannover and the Institute of Joining and Assembly (IFMT) at Chemnitz University of Technology are investigating the influence of the individual steps in the process chain on the local fatigue strength.
    Team: Abdelmonaem, Abdallah
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 01/2025 - 07/2027
  • SPP 2231 FLuSimPro – Coupling of experimental and numerical methods for the multi-scale analysis of the mechanisms of action of cooling lubrication strategies in machining processes (KexNuMe-KSS)
    Cutting fluids influence (CF) the thermomechanical tool load and can increase both component quality and chip volume. However, the supply of cooling lubricants is associated with high energy consumption. A targeted design of the CF-supply has the potential to increase the energy efficiency of cutting processes. However, this requires an understanding of the fundamental mechanisms of action, which are currently still unclear. To this end, novel in-situ measurement methods for thermomechanical cutting wedge load are being developed to understand the mechanisms of action of the CF along the cutting wedge.
    Team: Schenzel, Jan
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 01/2025 - 12/2026
  • TETO - Entwicklung eines innovativen Mehrkoordinatenantriebes für biomedizintechnische Tension-Torsion-Prüfanwendungen mit gesteigerter Leistungsdichte
    A common testing method for prostheses is the application of dynamically superimposed tension and torsion loads. Due to the decreasing age of patients, increasingly dynamic loads must be simulated in order to reflect real-life conditions. As part of the TETO project, a tension-torsion testing machine with increased power density is being developed to meet these growing requirements. To this end, a multi-coordinate drive developed for the first time by IFW, which combines a translational and a rotational axis, is being further developed. This eliminates the need for conventional serial kinematics, resulting in reduced wear and increased dynamics and precision.
    Team: Manthei, Julian
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 11/2025 - 05/2028
  • DFG Kornbeschichtung
    Die steigenden Anforderungen an die Leistungsfähigkeit moderner Fertigungsprozesse erfordern kontinuierliche Innovationen in der Schleiftechnologie. In diesem Projekt werden die Zusammenhänge zwischen Kornbeschichtung, Sinterprozess und Interface-Eigenschaften untersucht, um das Einsatzverhalten metallisch gebundener Schleifscheiben mit beschichteten Diamantkörnern zu verbessern. Ziel des Forschungsvorhabens ist es, auf Basis des gewonnenen Wissens Schleifwerkzeuge zu entwickeln, die eine höhere Verschleißfestigkeit aufweisen, effizienter arbeiten und gleichzeitig die Qualität der bearbeiteten Werkstücke verbessern.
    Team: Friedrich, Maren
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 05/2025 - 04/2028
  • Investigations into the influence of the manufacturing process on the properties of vitrified-bonded diamond grinding wheels
    Increasing demands on efficiency and quality in precision grinding require tools with defined properties. Although bonding chemistry and sintering mechanisms are fundamentally known, there is a lack of quantified correlations between raw materials, manufacturing steps, and the application behavior of vitrified-bonded diamond grinding tools. The project closes this gap and enables knowledge-based, process chain-wide optimization. The aim of the project is therefore to identify influencing factors and their interactions along the entire process chain and to combine them in a knowledge-based design model.
    Team: Geschwind, Thomas
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 04/2025 - 12/2028
  • HyPo – Modeling of the laser additive welding process considering the resulting properties of hybrid porous structures
    The DFG-funded project HyPo-A05 is part of the Transregional Collaborative Research Center TRR 375 and involves the development of a multi-scale simulation environment for the Laser Directed Energy Deposition (L-DED) process. By coupling physical models at the micro-, feature-, and component levels, residual stresses and material properties of hybrid porous structures can be predicted. The goal is to enable targeted process design for the local tailoring of properties in metallic functional components.
    Team: Ben Salem, Mariem
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 01/2025 - 12/2027
  • Modeling the cooling effect in tool grinding considering process-induced uncertainties
    In tool grinding, cooling and heat dissipation are critical factors for quality and tool life. Within the DFG Priority Program SPP2231, a multi-scale simulation system is being developed that couples material removal with thermo-fluid dynamics. The system accounts for process-induced uncertainties and ultimately enables demand-oriented supply of cutting fluids. This approach allows for targeted process design with reduced energy and resource consumption.
    Team: Wiesener, Frederik
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 01/2025 - 12/2026
  • VisionAdapt – Imaging-based chip formation detection for enhancing autonomy in high-dynamic turning processes
    Long chips in turning can lead to process interruptions and tool damage. The additional degree of freedom offered by 3-axis simultaneous turning provides new opportunities to address this challenge. In the ZDIN transfer project VisionAdapt, Leibniz University Hannover (IFW), the German Research Center for Artificial Intelligence (DFKI), and Technical University Braunschweig (IK), in collaboration with DMG MORI AG, are developing a system for this process that detects critical chip forms and automatically adapts the manufacturing process.
    Team: Zender, Felix
    Year: 2025
    Funding: Zukunft.Niedersachsen – ZDIN Transferprojekt
    Duration: 04/2025 - 03/2026
  • WiToPro – Method for knowledge-based tolerance assignment and function-oriented process design
    In the DFG-funded project WiToPro, the IFW, in collaboration with the Product Life Cycle Management group (PLCM) in Darmstadt, is developing a method for knowledge-based tolerance assignment and function-oriented process design. By ensuring seamless information flow between product development and manufacturing planning, geometric deviations, manufacturing effort, and process limits are considered jointly for the first time—resulting in higher quality, reduced production effort, and shorter development times.
    Team: Skryhunets, Andrii
    Year: 2025
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 03/2025 - 07/2027
  • AQ-ZirkonDent-HFB Automated quality control for rare earth stabilised zirconium dioxide dental implants with high strength and fracture toughness
    Medical implants are subject to strict quality controls, as undetected defects can, in the worst case, lead to replacement and thus to further surgery. In the ‘AQ-ZirkonDent-HFB’ project, Moje Keramik-Implantate GmbH & Co. KG and the Institute for Production Engineering and Machine Tools (IFW) at the University of Hanover are therefore developing automated quality monitoring for ceramic dental implants.
    Team: Krombach, Paul
    Year: 2025
    Funding: Zentrales Innovationsprogramm Mittelstand - ZIM
    Duration: 08/2025 - 07/2028
  • EmSim - Method for determining adaptive monitoring limits
    Process monitoring systems are often designed for series production and use direct or indirect sensor signals that require complex calibration. The development of model-based simulation approaches and machine learning methods offer the potential to design adaptive monitoring limits more efficiently. However, solutions that take into account dimensional tolerances, component geometries and machining operations in single-part production are lacking. The development of such adaptive methods could revolutionise process planning and quality assurance. In this project, we are therefore researching a method for the adaptive generation of process monitoring limits in process planning for machining production.
    Team: Martin Winkler
    Year: 2024
    Funding: German Research Foundation - DFG
    Duration: 01/24 - 12/26
  • Combined production of AISI H13 tool steel using laser-based additive manufacturing and mechanical post-processing to increase service life and durability
    The additive manufacturing of H13 tool steel using laser-based powder bed fusion (PBF-LB) enables innovative designs in toolmaking, such as internal cooling channels in die-casting or injection molding tools, which increase their service life. However, due to insufficient dimensional accuracy and high roughness resulting from additive manufacturing, the components require machining or forming as a finishing process. This finishing step has a significant impact on surface and subsurface properties. By specifically characterizing and adjusting these properties during the manufacturing and finishing process, a new generation of optimized H13 tools is being developed that surpasses the properties of reference tools.
    Team: Philipp Pillkahn
    Year: 2024
    Funding: German Research Foundation – DFG
    Duration: 09/2024 – 09/2027
  • Stein 2 – Investigation of the Relationships Between the Properties, Grinding Processes, and Application Behavior of Stones as Cutting Material
    Natural stones such as flint or quartz offer the potential to replace energy- and resource-intensive cutting materials like cemented carbide. The project investigates how targeted control of the material properties and grinding processes of stones can enhance their performance as tool cutting materials, with the aim of developing sustainable and cost-efficient alternatives for industrial machining applications.
    Team: Marra Araujo, Lucas
    Year: 2024
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 11/2024 - 10/2027
  • Integrated component monitoring of highly loaded hybrid porous components
    Within TRR 375, multifunctional, high-performance components made from hybrid porous (HyPo) materials are being developed. These components combine metallic materials with tailored porosity to provide locally varying densities and application-specific mechanical and thermal properties. Integrated sensing and residual stress analysis extend their functional scope. Subproject A04 is developing condition monitoring based on integrated sensing throughout the entire life cycle. This includes analysing the residual stress of highly loaded HyPo components in order to reconstruct the load history and enable predictive service-life assessment.
    Team: Nordmeyer, Henke
    Year: 2024
    Funding: Deutsche Forschungsgemeinschaft - DFG (Sonderforschungsbereich HyPo)
    Duration: 04/2024 / 12/2027
  • SFB1368 C04 – Cooling concepts for grinding
    Grinding titanium alloys is particularly challenging due to the low thermal conductivity and reactive properties of the material. The oxygen present in the process influences friction, wear, and material separation, which can reduce process stability and component quality. The project investigates grinding under oxygen-free conditions in order to better understand the interactions between the abrasive grain, the workpiece, and the atmosphere. The aim is to analyze the tribomechanical and thermochemical mechanisms of grinding and thus lay the foundations for optimized machining of reactive materials.
    Team: Michael Zenger
    Year: 2024
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 01/2024 – 12/2027
  • CRC 1368 – Oxygen-free production – B03 chemical mechanismen in titanium machining
    During the machining of titanium materials, high temperatures and the presence of atmospheric oxygen cause oxidation processes on the tool, workpiece and chips. This leads to increased tool wear, alters the subsurface properties of the components and reduces the recyclability of the chips. This project therefore investigates the effect of an oxygen-free atmosphere on these mechanisms. To this purpose, a gas mixture of argon and silane is supplied during machining, which almost completely replaces the atmospheric oxygen and prevents oxidation processes. The objevtive is to analyse the relationships between oxygen content, chip formation, thermomechanical load and tool wear and to derive potential for reducing wear and increasing energy and resource efficiency.
    Team: Schaper, Florian
    Year: 2024
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 01/2024 - 12/2027
  • Model-based analysis of the effects of bonding properties and thermomechanical influences on the grain–bond interface during grinding with sintered metal-bonded tools.
    Sintered metal-bonded CBN grinding wheels exhibit elastoplastic bond deformations in operation, affecting the topography, forces, and surface roughness of workpieces—so far without reliable models. The DFG-funded project links single-grain scratch tests with force and temperature measurements and finite element simulations, transfers the results into an empirical process model, and integrates them into the kinematic simulation IFW CutS for predicting surface quality and tool behavior.
    Team: Wulf, Michael
    Year: 2024
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 12/2024 - 11/2026
  • Material separation mechanisms during rough grinding with large CBN grains
    Large CBN abrasive grains (>300 µm) open up new productivity regimes in rough grinding, yet the chip formation mechanisms and thermomechanical loads are scarcely understood. The project investigates chip formation, heat flow, and forces in HSG/HEDG experimentally and via simulation. The outcome is a scale-bridging model for designing coarse-grained CBN grinding processes with maximum material removal while ensuring surface/subsurface integrity.
    Team: Puls, Lennart
    Year: 2024
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 06/2024 - 12/2026
  • Method for predictive cost calculation of machined parts for quotes, taking into account the risk of changes in production
    Contract manufacturers calculate their quotes based on planned production routes. This planning is at risk of disruption due to rush orders, breakdowns of machines or staff absences, as well as deviations in the production process. This results in cost deviations that lead to economic risks. The SzenoKalk project is developing methods to systematically record rescheduling risks and incorporate them into quotation calculations. The goal is to achieve a realistic, data-based, and automated manufacturing cost estimate for machined components.
    Team: Marcus Nein
    Year: 2024
    Funding: Bundesministerium für Wirtschaft und Klimaschutz (BMWK)
    Duration: 11/2024 - 10/2026
  • Active vibration damping of a machining robot with hybrid drive
    The increasing use of industrial robots in machining promises flexibility and cost-efficiency. However, this comes with challenges such as low gearbox stiffness and susceptibility to vibrations in the robot axes. In contrast, machine tools offer higher precision but are significantly more expensive to purchase. In our project we develop a model-based control method for active vibration damping. This is intended to improve the machining accuracy of industrial robots.
    Team: Taha Araoud
    Year: 2023
    Funding: German Research Foundation – DFG
    Duration: 10/23 - 07/26
  • DFG Schtein – Development of PVD-coated tools made of rock
    The production of conventional cutting materials such as cemented carbide requires questionable raw materials (tungsten, cobalt). This dependence can be reduced by expanding the range of cutting materials. Naturally occurring rocks offer potential; PVD coatings could enhance their applicability. The influence of mechanical/chemical pretreatments on the surface, coatability, and adhesion is being investigated. This will lead to the development of suitable coating systems, the analysis of their mechanisms of action, and the analysis of wear on coated tools during turning of aluminum alloys.
    Team: Dr. Hilke Petersen
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 11/2023 - 10/2026
  • MPS II – Multi-Coordinate Positioning System for Machining Tools
    Serial feed axes limit the dynamic performance and accuracy of machine tools. MPS II investigates a novel positioning system that combines a synchronous planar motor with active magnetic guidance. The aim is to achieve high stiffness, friction-free guidance, and precise motion in six degrees of freedom, thereby improving path quality and productivity in industrial applications.
    Team: Roham, Hamed
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 04/2023 - 04/2026
  • KontROLL - Contact stress–controlled deep rolling process
    Deep rolling increases the service life of cyclically loaded components by plastically deforming the surface layer. To achieve optimal results, the correct rolling force must be applied. For this purpose, the ECOROLL AG Werkzeugtechnik and the Institute of Production Engineering and Machine Tools (IFW) are jointly developing a model-based control method for the process. This approach ensures optimal effectiveness of deep rolling while maintaining simple and user-friendly process application.
    Team: Berlin, Jan
    Year: 2023
    Funding: ZIM
    Duration: 12/2023 - 02/2026
  • OptiWas – Methodology for optimizing the interdependencies between additive and subtractive manufacturing
    Additive and subtractive manufacturing combined offer significant potential for complex lightweight structures. Targeted stiffening of additively manufactured blanks can reduce vibrations during subtractive machining. In the DFG-funded project OptiWas, the IFW is developing a methodology to systematically analyze these interdependencies and make the insights usable for future product generations. This approach significantly enhances the efficiency of hybrid manufacturing processes
    Team: Schlenker, Fabian
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 09/2023 - 08/2026
  • AutoBohr - System zur autonomen Prozessüberwachung von Bohrprozessen
    The AutoBohr project is developing an autonomous and robust monitoring system for drilling processes in single-part and small-batch production. By merging machine and acceleration signals, tool wear is reliably detected. In addition, impending anomalies such as tool breakage can be detected early and prevented. New classification methods enable reliable evaluation despite despite various disruptive influences such as chip jams. The goal is a self-parameterizing system that reliably monitors drilling processes without reference runs, avoids false alarms, and reduces production downtime.
    Team: Tkachuk, Kirill
    Year: 2023
    Funding: Zentrales Innovationsprogramm Mittelstand - ZIM
    Duration: 10/2023 - 02/2026
  • Optidrap - Model predictive impedance control of pneumatic continuum actuators in the continuous wet draping process
    As part of the “OptiDrap” project funded by the German Research Foundation (DFG), the IFW is conducting research on the automation of processes for manufacturing fiber composite components with highly complex shapes. The objective is to automate the previously predominantly manual deposition of semi-finished products using a continuous wet draping (CWD) process.
    Team: Wolf, Lucas
    Year: 2023
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 12/2023 - 11/2026
  • SHOREliner - Development of a climate-neutral fiber composite aircraft with robust aerodynamic and STOL characteristics for use as a multi-purpose commuter aircraft
    In the SHOREliner project, the IFW is developing the basis for the CO2-neutral and resource-efficient serial production of the 100% battery-electric MDA1 eViator from consortium partner MD Aircraft. The challenge lies in the frequent late and cost-intensive consideration of manufacturing aspects, especially within small and medium-sized enterprises (SMEs). The IFW is therefore focusing on a multidisciplinary method: Using digital twins and manufacturability analyses, process chains are optimized from the start, the development process is shortened, and resource consumption is reduced.
    Team: Tiemann, Tim; Garthe, David
    Year: 2023
    Funding: BMWE (LuFo VI-3)
    Duration: 01/2023 - 12/2026
  • Exzellenzclusters PhoenixD - Task Group M4: Machines, Automation and Organization
    Our research mission is to create precise machine actuators and flexible factory concepts for multimodal optics manufacturing. We are developing a precise, sensor-integrated actuator for the individual manufacturing processes devised within the working groups of the M – Manufacturing research focus. With it, process parameters can be adjusted, thereby increasing manufacturing accuracy. In addition, we link the processes in a modular and flexible way into a so-called Smart Manufacturing Grid (SMG), enabling cost-effective production starting from a lot size of one.
    Team: Zhang, Jingcai
    Year: 2022
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 12/2022 - 12/2025
  • TowPregRod – Efficient process for the continuous production of CFRP lightweight rods
    The project partner Schütze GmbH & Co is currently producing lightweight aerospace rods in CFRP sandwich design using an extrusion process in which a cylindrically shaped core material is covered with resin-impregnated carbon fibres parallel to the longitudinal axis of the rod. The unidirectionally reinforced sandwich rods have very good weight-related mechanical properties and are used, for example, as lightweight, highly rigid and high-strength structural stiffening components such as support struts or steering rods. However, the current process only allows the production of fibre layers oriented unidirectionally in the longitudinal direction of the rod; angled layers must be produced separately in an offline process. The continuous introduction of angled layers in the production process and the use of pre-impregnated fibre rovings significantly expand the range of applications for sandwich rods and enable resource-saving, future-oriented production.
    Team: Marco Bogenschütz
    Year: 2021
    Funding: BMWK im Rahmen des Luftfahrtforschungsprogramms (LuFo)
    Duration: 06/21 - 02/26
  • SFB 298 SIIRI – Saftey Integrated and Infection Reactive Implants – A04 Demand-oriented design and manufacture of damage-tolerant implant junctions
    To improve the adaptation of hip endoprostheses to individual patient anatomy, bimodular hip endoprostheses enable improved care. However, this modularity includes an additional interface to the implant, where micromotions can lead to wear and implant failure. It is therefore important to understand the interactions between the failure mechanisms of the interfaces and the surface topographies. The goal is to use manufacturing technology and mechanical engineering to develop damage-tolerant implant interfaces.
    Team: Legutko, Beate
    Year: 2021
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 06/2021 - 12/2025
  • SFB 298 SIIRI - Sicherheitsintegrierte und infektionsreaktive Implantate – A01 Implantatregeneration und Lebenszyklusmanagement
    Knee endoprostheses are among the most commonly used implants, but with a failure rate of around 13% within ten years, there is considerable room for improvement. One of the main reasons for this is wear and tear on the polyethylene inlay, which is often only detected late in clinical routine because the abrasion is barely visible on X-rays. This results in high costs for surgeons and implant manufacturers, stress for patients, and challenges in planning revision surgery. A digitally supported system that consolidates data from different phases of the implant's life and predicts wear processes can improve targeted interventions and avoid unnecessary revisions.
    Team: Eggers, Max-Enno
    Year: 2021
    Funding: Deutsche Forschungsgemeinschaft - DFG
    Duration: 06/2021 - 12/2025

Last Change: 14.10.25 Print

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