Laboratory / lab for machining

Hermle C30

The three-axis machine with a maximum speed of 10,000 rpm and a working area of 650x600x500 is particularly suitable for machining steel and cast iron. It is equipped with high-pressure internal cooling lubrication and minimum quantity lubrication, which is possible either from the outside or through the spindle.

Machine characteristics:

• Assignment, credit, performance: 32 kW (20% ED)
• Torque: 200Nm (20% ED)
• Maximum speed: 10,000 1/min
• Tool holder: HSK 63 A

Spinner TC 600

lathe
Spinner TC 600-65

• Assignment, credit, performance: 18 kW (S3/60% ED)
• Torque: 348 Nm (S3/60% ED)
• Maximum speed: 4,000 1/min
• Tool holder: VDI30
• Driven tools
• y-axis
• Accuracy version with linear scales

Shrinking unit Bilz ISG 2200 WK

(for shrinking carbide and steel tool shanks into shrink fit chucks. Very fast cooling is possible due to the water cooling)

Bilz FWG 3100 balancing device

(for measuring the balancing condition of tools and tool holders)

Kelch Kalimat C tool presetter

(for tool presetting; measuring the diameter and length of the tools, the flight of the individual cutting edges, etc.)

Mitutoyo TM-505 measuring microscope

(with PC-supported image acquisition and evaluation)

Mitutoyo SJ-301 roughness measuring device

(PC-supported)

• Atlas A9 measuring PC
• 4-component force measuring platform Kistler for drilling (Fx, Fy, Fz, Mz)
• 3-component force measuring platform Kistler for milling (Fx, Fy, Fz)
• 3-component force measuring platform Kistler for turning (Fx, Fy, Fz)
• Keyence VHX 500-F 3D digital microscope
• Infratek 107A power meter
• SpeedCam MiniVis e2 high-speed camera
• Vibration measurement technology (impulse hammer, sensors, data collection, data capture)

• Various vibration sensors
• Equipment for non-contact vibration measurement
• Coordinate measuring machines (Zeiss Prismo and Zeiss UPMC)
• Roughness measuring devices
• Optical topography measuring device
• Leitz VMM 200+ measuring microscope
• Scanning electron microscope
• Renishaw laser interferometer
• Metallography Institution
• Computer tomograph

Prof. Kalhöfer currently teaches the lectures

• Separation processes,
• production,
• machine tools and
• special fields of machining

are held by Prof. Kalhöfer.

The cutting processes lecture for students on the Mechanical Engineering/Production Technology degree programme covers the special fields of shear cutting, spark erosion and electrochemical machining in addition to cutting.

Production Engineering is held for students of general Mechanical Engineering. It includes the essential areas of production, in particular primary and secondary forming, cutting and joining. The focus is on metalworking.

The lecture Machine Tools for the Mechanical Engineering/Production degree programme covers the basics of machine tool construction with the requirements, design and layout of machine tool components. The basics of designing production systems are also addressed.

Modern Machining Technology for the Master's degree programme in Product Development and Manufacturing takes an in-depth look at various current topics in machining. In addition, an extensive laboratory project is carried out here to train independent planning and working in a team on a machining topic.

Studies and Diplom theses deal with various topics from the fields of machining and laser technology.
Examples of this include the production of pressure and gravity die casting molds, which are then used in the foundry laboratory.

The research activities of the Endowed Chair of Machining are in the field (of) machining with geometrically defined cutting edges.
Completed and ongoing research projects are:

• Drilling and reaming of stainless steel (funded by the state of Baden-Württemberg),
• High-performance drilling of austenitic stainless steel (funded by the BMBF),
• Further development of a parting-off tool (in cooperation, cooperative venture partnership, collaboration with the Institute for Materials Engineering, funded by the BMWi)
• Investigations/analyses and optimization of tool vibrations during machining (funded by the state of Baden-Württemberg)

Another research topic is energy-efficient manufacturing.
Completed and ongoing research projects are in this field (of):

• Energy saving potentials in lathes (funded by the state of Baden-Württemberg),
• Energy-efficient tool concepts for machining (funded by the state of Baden-Württemberg).

Kalhöfer, E.: Trockenbearbeitung mit geometrisch bestimmem Schneide, 9th Darmstadt Production Symposium "Precise Machining at High Speeds", Darmstadt, February 27/28, 1996.

Kalhöfer, E.: HSC-Fräsen von Leichtmetallguss, accompanying talk; lectures at euroguß 96, Untertürkheim, 18.04.1996.

Kalhöfer, E.: High Speed Cutting - an Overview, Conference on High Speed Cutting, DTI Taastrup, Copenhagen, Denmark, 05.12.1996.

Kalhöfer, E.: The Technology of High Speed Cutting, 4th International Conference on Production Engineering, Opatija, Croatia, 12/13.06.1997.

Kalhöfer, E.: Dry Machining - Principles and Applications, 2° Seminário International de Alta Tecnologia "Usinagem com Altíssima Velocidade de Corte e Alta Presicao", Sta. Bárbara d'Oeste, Brazil, 31.07.1997.

Kalhöfer, E.: Einsatz der Hochgeschwindigkeitsbearbeitung bei der Herstellung von Karosseriewerkzeugen, Fachtagung Automobil 2010, Design, Konstruktion und Fertigung im Wandel, Bad Nauheim, 12/13.03.1998.

Kalhöfer, E.: Dry Machining - Technology and requirements to the machine tool, International Conference on Improving Machine Tool Performance, San Sebastian, Spain, 06.-08.07.1998.

Kalhöfer, E.: Valid from, trends and potentials of high-speed machining, AWF-Erfahrungsforum Potentiale und Trends der Hochgeschwindigkeitsbearbeitung, Stuttgart, 25.09.1998.

Kalhöfer, E.: Prediction of Tool Life and Optimization of Cutting Parameters with Artificial Neural Networks, II CIRP International Workshop on Modelling of Machining Operations, Ecole Centrale de Nantes, Nantes, 25./26.01.1999.

Kalhöfer, E.: Forecast of Tool Life and Optimization of Cutting Parameters with Artificial Neural Networks, Sino-German Joint Symposium on High Speed and High Precision Machining, National Cheng Kung University, Tainan, Taiwan, 15-17.03.1999.

Kalhöfer, E.: High Speed Machining - History, Technology and Machine Tools, Materials Processing Awareness Workshop High Speed Machining, Sheffield Hallam University, Sheffield, England, 23.06.1999.

Kalhöfer, E.: Manufacturing Engineering for High Volume Production of CGI Engine Blocks - Redesign of an Existing Grey Iron Line to CGI, CGI Machining Workshop, Darmstadt, Germany, 02.11.2000.

Kalhöfer, E.: Neue Dienstleistungen in der Automobilindustrie, Festkolloquium zur Einweihung des Dienstleistungszentrums der Firma Mapal Dr. Kress KG, Aalen, 25.09.2003.

Kalhöfer, E.: Dry machining and minimum quantity lubrication, IHK-Bildungszentrum Aalen, 08.12.2005.

Kalhöfer, E.: Trockenbearbeitung heute: Potential, prerequisite(s) und wirtschaftlicher Nutzen, LMT-Symposium, Oberkochen, 31.03.2006.

Kalhöfer, E.: Resource-saving production, innovative tool systems for the production of tomorrow, Tool Symposium 2008, Schwarzenbek, 20.06.2008.

Kalhöfer, E., Rief, M., Schmutz, M.: Energieeffiziente Werkzeugkonzepte, talk; lecture at Mapal Press Day, 10.06.2010.

Kalhöfer, E., Rief, M.: MQL needs less Energy, talk; lecture at the LMT trade fair appearance at the AMB on 29.09.2010, lmt.e-convention.net/deutsch/amb-archiv/vortrag-professor-kalhoefer/-vortrag-professor-kalhoefer.html.

Kalhöfer, E., Rief, M.: Energyeffizienz in der Metallbearbeitung, talk; lecture at IHK event (general) Machining - Material und Energy sparen. Heidenheim, 09.11.2010.

Schulz, H., Kalhöfer, E.: Environmentally friendly production possible through dry machining? Topic Research 2/1996, p. 16-23.

Schulz, H., Kalhöfer, E.: Now also shrink-fit steel shanks! Workshop und Betrieb 129 (1996) 9, pp. 774-776.

Schulz, H., Kalhöfer, E.: Dry machining of wrought aluminum alloys, Werkstatt und Betrieb 129 (1996) 7-8, pp. 707-710.

Kalhöfer, E.: Aluminum in the vehicle, conference report, Werkstatt und Betrieb 130 (1997) 6, p. 479.

Kalhöfer, E.: Flexible with milling machines and machining centers, trade fair report, Werkstatt und Betrieb 130 (1997) 12, pp. 620-623.

Kalhöfer, E.: Always more productive gear cutting, trade fair report, Werkstatt und Betrieb 130 (1997) 12, pp. 1123-1125.

Kalhöfer, E.: Milling and drilling faster and faster, trade fair report, Werkstatt und Betrieb 130 (1997) 12, pp. 1098-1105.

Schulz, H., Kalhöfer, E.: Dry high-speed machining in aluminum, wt Werkstattstechnik 87 (1997), pp. 471-474.

Schulz, H., Kalhöfer, E.: Predicting tool life, Werkstatt und Betrieb 131 (1998) 5, pp. 374-375.

Schulz, H., Kalhöfer, E.: Zerspanungsparameter mit neuronalen Netzen bestimmen, wt Werkstattstechnik 88 (1998) 3, p.125-128.

Schulz, H., Kalhöfer, E., Troschel, W., Sahm, D., Reuter, U.: Zerspanen mit GGV, Werkstatt und Betrieb 131 (1998) 3, pp. 135-137.

Kalhöfer, E.: High-performance tools, conference report, Werkstatt und Betrieb 132 (1999) 1-2, p. 83.

Kalhöfer, E., Salomon, M., Schilling, R.: Comparison of parallel and serial manufacturing concepts, Werkstatt und Betrieb 138 (2005) 5, pp. 40-44.

Kalhöfer, E., Kranzen, J.: Euphoria gives way to sober assessment - Valid from implementation and barriers to introduction of dry machining, Werkstatt und Betrieb 139 (2006) 7-8, pp. 52-54

Kalhöfer, E.: Unused savings potential in machining, Economic Engineering 5/2008, pp. 56-599.

Kalhöfer, E.: Energieeffiziente Werkzeugkonzepte in der Zerspanung, Werkstatt und Betrieb 141 (2008) Heft 10, S. 36-39.

Kalhöfer, E., Kranzen, J.: Influencing edge zone hardening when drilling stainless steels, horizonte No. 33, 2009, pp. 8-11.

Kalhöfer, E., Kranzen, J.: Drilling stainless steels, Werkstatt und Betrieb 142 (2009) No. 3, pp. 12-15.

Kalhöfer, E., Kranzen, J.: Drilling of stainless steels, Part 2, Geometry and coating, Werkstatt und Betrieb 142 (2009) Heft 9, S 66-68.

Kalhöfer, E., Rief, M.: Energieeffiziente Werkzeugkonzepte in der Zerspanung - Analyse des Energieverbrauchs von spanenden Werkzeugmaschinen, horizonte Nr. 34, 2009, S. 30-33.

Kalhöfer, E.: Formas de evitar desperdicios de energia nos processos de usinagem, MM Maquinas e Metais, February 2010, Brazil

Kalhöfer, E., Kranzen, J.: Investigations/analyses of cutting temperatures during drilling using thermography, horizonte No. 35, 2010, pp. 32-34.

Rief, M., Kalhöfer, E., Karpuschewski, B.: Energy value of different cooling lubrication systems. Workshop and operation. 2010, 09/2010, S. 142-145.

Kalhöfer, E., Kranzen, J.: É possível otimizar os parâmetros de corte e a qualidade das pecas de acos inoxidáveis, MM Maquinas e Metais, December 2010, Brazil.

Kalhöfer, E. and Rief, M.: Synchronization errors during tapping, Werkstatt und Betrieb 2011, 04-2011, pp. 68-71.

Karpuschewski, B., Kalhöfer, E., Rief, M.: Quantification of the time and energy saving potential of step drilling tools, VDI-Z I-2011, pp. 14-16.

Karpuschewski, B., Kalhöfer, E., Joswig, D., Rief, M.: Energiebedarf für die Hartmetallherstellung, ZWF Zeitschrift für wirtschaftlichen Fabrikbetrieb 7/8-2011, pp. 496-501.

Karpuschewski, B., Kalhöfer, E., Joswig, D., Rief, M.: Energiebedarf bei der Herstellung von Hartmetall-Wendeschneidplatten, ZWF Zeitschrift für wirtschaftlichen Fabrikbetrieb 9-2011, pp. 602-605

Karpuschewski, B., Kalhöfer, E., Rief, M.: Energy requirements in the production of solid carbide twist drills, VDI-Z Spezial Werkzeuge 8-2011, p. 59-61.

Rief, M., Kalhöfer, E., Karpuschewski, B.: Influence of the coolant lubrication concept on Energy and cost efficiency, Werkstatt und Betrieb 2011, 09-2011, pp. 152-155.

Karpuschewski, B., Kalhöfer, E., Rief, M., Joswig, J.: Ermittlung der Kühllast durch Bearbeitungsmaschinen für die Auslegung von Klimaanlagen, HLH 10-2011, pp. 41-44.

Kalhöfer, E.: Chapter Dry machining in: Schulz, H. (ed.): Hochgeschwindigkeitsbearbeitung, Carl Hanser Verlag, 1996.

Kalhöfer, E.: Schnittwertoptimierung mit Hilfe künstlicher neuronaler Netze, doctoral thesis, Shaker Verlag, 1998.

Kalhöfer, E.: Chapter Qualification of Machine Tools in: Industrielle Fertigung, Volume 2: Messen und Prüfen, Europa-Verlag, 2006.

Kalhöfer, E.: Skills that complement each other - machining, forming, surface treatment. In: Zukunftsregion Ostwürttemberg, monographs of German commercial economic areas, Verlag Kommunikation & Wirtschaft GmbH, 2008