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Projects / Programmes source: ARIS

DEVELOPMENT AND PRODUCTION OF TAYLOR MADE MILLING TOOLS, COATINGS AND CORRESPONDING MANUFACTURING TECHNOLOGIS IN INDIVIDUAL TOOLING INDUSTRY

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Research activity

Code Science Field Subfield
2.10.00  Engineering sciences and technologies  Manufacturing technologies and systems   

Code Science Field
T130  Technological sciences  Production technology 

Code Science Field
2.03  Engineering and Technology  Mechanical engineering 
Keywords
custom made mills (cutters), tool geometry, individual production, multilayer coating, nanostructured coating, tool life
Evaluation (rules)
source: COBISS
Evaluation of bibliographic research performance indicators according to ARIS methodology
Citations Citations for bibliographic records in COBIB.SI that are linked to records in citation databases
source: WoS source: Scopus source: COBISS
Researchers (26)
no. Code Name and surname Research area Role Period No. of publications
1.  20863  PhD Tomaž Berlec  Manufacturing technologies and systems  Researcher  2015  351 
2.  13093  Matija Bizjak  Mechanics  Researcher  2014 - 2017  95 
3.  18271  PhD Miha Čekada  Materials science and technology  Researcher  2014 - 2017  439 
4.  31250  PhD Luka Čerče  Manufacturing technologies and systems  Researcher  2014 - 2017  54 
5.  22240  PhD Radovan Dražumerič  Manufacturing technologies and systems  Researcher  2014 - 2017  78 
6.  38903  Jaka Dugar  Manufacturing technologies and systems  Researcher  2016  43 
7.  20359  Renato Fijavž  Mechanics  Researcher  2014 - 2017  32 
8.  37944  Marija Jeretina    Technical associate  2015 - 2016  0 
9.  06883  PhD Janez Kopač  Manufacturing technologies and systems  Researcher  2014 - 2016  1,837 
10.  20361  Martin Korenjak  Mechanics  Researcher  2014 - 2017  0 
11.  38896  PhD Matjaž Kos  Manufacturing technologies and systems  Technical associate  2016  27 
12.  23470  PhD Peter Krajnik  Manufacturing technologies and systems  Researcher  2014  235 
13.  17076  PhD Davorin Kramar  Manufacturing technologies and systems  Researcher  2014 - 2017  447 
14.  05571  PhD Janez Kušar  Manufacturing technologies and systems  Researcher  2015  623 
15.  19093  PhD Matjaž Milfelner  Manufacturing technologies and systems  Researcher  2014 - 2017  201 
16.  09090  PhD Peter Panjan  Materials science and technology  Researcher  2014 - 2017  792 
17.  34413  PhD Urban Pavlovčič  Computer science and informatics  Researcher  2016  51 
18.  26559  PhD Franci Pušavec  Manufacturing technologies and systems  Head  2016 - 2017  610 
19.  18047  Vinko Rotar    Technical associate  2014  38 
20.  15604  Tomaž Sirnik    Technical associate  2014 - 2017  0 
21.  09001  PhD Mirko Soković  Manufacturing technologies and systems  Researcher  2014  1,076 
22.  20358  MSc Andrej Stepišnik  Mechanics  Researcher  2014 - 2017  12 
23.  20362  Miran Šrot  Mechanics  Researcher  2014 - 2017  0 
24.  31294  Srečko Štefane    Researcher  2014 - 2017  0 
25.  29856  Gašper Vidic  Mechanical design  Researcher  2015  41 
26.  07855  Anton Žličar  Mechanics  Researcher  2014 - 2017  82 
Organisations (3)
no. Code Research organisation City Registration number No. of publications
1.  0106  Jožef Stefan Institute  Ljubljana  5051606000  90,682 
2.  0405  EMO - ORODJARNA proizvodna družba d.o.o. (Slovene)  CELJE  5453364  198 
3.  0782  University of Ljubljana, Faculty of Mechanical Engineering  Ljubljana  1627031  29,207 
Abstract
The increasing implementation of advanced high strength steels (AHSS) in the automotive sector is achieving great results in terms of weight and security in the car bodies. Last analysis pointed out that the main automotive brands uses up to 70% of AHSS in their car bodies. Unfortunately, although many efforts have been carried out from the point of view of materials and design strategies, the bottle neck of current AHSS solution in the automotive industry relies in the manufacturing processes of the stamping tools. On the one hand, the response of such material during forming and after forming changes very much compared to traditional low strength steels being the tool definition and the process set up much more complicated. In parallel, the high strength of the materials generates high wear in the stamping tools increasing their maintenance cost. Finally, it must also been considered that tougher materials must be used to construct the tools because the forming forces can be up to four times bigger compared to traditional steels. In this scenario, the fabrication of stamping tools for AHSS becomes a great challenge because harder materials must be machined and adequate milling tools, in terms of optimal milling tool geometry and coating must be defined. As a result to all these drawbacks, it is estimated that the cost of a tool for stamping AHSS compared to the cost of a tool for stamping traditional steels can be up to three times bigger. The present project aims at developing advanced solutions for offering to the automotive sector reliable and affordable stamping tools for the manufacturing of sustainable light weight designs. Novel milling solutions are expected (selection of size, geometry and coatings of the cutters) for machining of advanced AHSS stamping tools. A cost reduction of up to 15% is foreseen in the manufacturing of the AHSS stamping tools. Today’s market offers only cutters of standard lengths, standard radius, standard quality of material, standard curve of helix, standard coating etc. which are suitable for mass production. For the individual production of stamping tools, which utilizes non-standard forms and shapes, changing conditions of milling and many other difficulties, different cutters are needed. This relates to materials, geometry and surface treatment. When it comes to the design of the cutting tool for machining hard materials both the low heat transfer rate and the low modulus of elasticity must be taken into consideration. To combat these constraints, high shear geometry must be incorporated. The proper cutting edge geometry can aid in providing a more predictable break-in period with reduced chatter. The chatter and vibrations can be reduced by selecting an appropriate length and rigidity of the tool. And finally coatings greatly increase the performance of cutting tools by providing a wear resistant, low friction, non-reactive barrier to the challenges of machining operations with difficult to machine workpiece materials. Overall tool selection procedure will be developed within the project.
Significance for science
The increasing implementation of advanced high strength steels (AHSS) in the automotive sector is achieving great results in terms of weight and security in the car bodies. Last analysis pointed out that the main automotive brands uses up to 70% of AHSS in their car bodies. Unfortunately, although many efforts have been carried out from the point of view of materials and design strategies, the bottle neck of current AHSS solution in the automotive industry relies in the manufacturing processes. Milling is a versatile cutting process used extensively in the machining of complex geometrical workpieces. It has become key technology in the manufacturing of dies and molds for aerospace and automotive components. Due to the flexibility of the cutting process and the different variables involved, optimization of the milling process has become a fundamental aspect in order to achieve higher productivity and quality. Therefore, a precise knowledge of the cutting process is required for the efficient definition of the machining operation. For this reason, tool manufacturers propose the use of machining strategies. A machining strategy establishes the working mode for a cutting tool in a machining operation and basically fixes the width and depth of cut, and the cutting trajectories. An in depth knowledge of the cutting tool performance is applied in each individual case. Owing to this, it is the tool manufacturers who propose the use of machining strategies for an efficient use of their cutting tools. In this project, from the scientific point of view, the objective was to explain analytically and experimentally the application of these novel techniques and strategies for machining hard stamping tool steels. For this purpose, a set of experiments have been carried out to compare conventional cutting with a new, where these strategies are applied. Strategies involve numerous parameters like milling tool geometry and shape, edge preparation, coating application and tool path generation. The cutting forces, tool wear progression, machined surface quality and some other machinability criteria have been analysed. In the project newly developed cutting mills (cutting tool geometry, cutting edge preparation, newly developed coatings) achieve significant improvement of tool live and stability in comparison with competing cutting tools producers. With an improved cutting strategy, shorter machining time at the same surface quality has been achieved.
Significance for the country
The production of AHSS stamping tools with these novelties will, on the one hand, open the low class cars market to technological advanced not foreseen nowadays, and on the other hand, expand the business of the SMEs involved in the project drastically. Consortium will develop a super cutter for the needs of individual automotive tools manufacturers, coated with nano coatings that will have greater durability. Production with such cutter will better, faster and cheaper. With the use of newly developed cutting tools, the machining time has significantly dropped, while the archived surface quality is equal. This means, that such a process is faster and therefore cheaper. The achieved results raises the visibility of the research institutions and companies both in Slovenia, the European and world market. In this case, the optimisation was carried out for only one company on a single segment of its applications. In addition to the extension of the methodology within the company, the presented methodology can be extend further throughout the Slovenian industry. Not only in the processing sector, but also in the sector of manufacturers of cutting tools. In this way the FS research team is already engaged. Results of the project will give manufacturing strategies that will allow better machinability of AHSS stamping tools. Products from these steels achieve higher strength car body structures, with lower weight, and result in fewer CO2 emissions compared to other body materials. Just as importantly, the AHSS products allow for improved safety performance, while meeting manufacturing cost limitations. Furthermore, proposed technological strategies includes all recommendation for sustainable manufacturing and is more environmental-friendly than current conventional technologies.
Most important scientific results Annual report 2014, 2015, final report
Most important socioeconomically and culturally relevant results Annual report 2014, 2015, final report
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