Dirk Biermann

Dirk Biermann
Technische Universität Dortmund | TUD · Institute of Machining Technology

Prof. Dr.-Ing. Prof. h.c.

About

587
Publications
76,603
Reads
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6,978
Citations
Citations since 2017
250 Research Items
4871 Citations
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201720182019202020212022202302004006008001,000
201720182019202020212022202302004006008001,000
Introduction
The Institute of Machining Technology (ISF), headed by Prof. Dr.-Ing. Dirk Biermann, has engaged since more than 40 years in research and education in all relevant machining processes and in the application of methods from computer science in machining. The investigated processes include turning, drilling, deep-hole drilling, milling, grinding, honing, and blasting. Several of these processes are performed in the high-speed (HSC) or high-performance (HPC) range or are to be qualified for these highly productive techniques in current research activities. Furthermore, micromachining (for drilling and milling), dry machining and minimal-quantity lubrication constitute central aspects of the research at ISF. The realization of virtual machining processes based on different modeling techniques
Additional affiliations
April 2007 - present
Technische Universität Dortmund
Position
  • Head of Department

Publications

Publications (587)
Article
The difficulties in the mechanical micro-machining process regarding the tool deflection, size effect and tool wear are much more pronounced than those in mechanical macro-machining. However, the role of mechanical micro-machining cannot be overestimated as an alternative against the non-traditional machining methods in manufacturing complex micro-...
Conference Paper
In micromachining, the manufacturing quality of the cutting tools as well as the condition of the cutting edges play a major role. However, achieving the desired quality of the micro cutting tools has been very challenging in the conventional grinding processes. A new approach for manufacturing micro cutting tools by precise electrochemical machini...
Article
The large tool length in BTA deep hole drilling often leads to strong torsional vibrations of the tool system, leading to a reduced bore hole quality failures. When substituting steel drill tubes with tubes from composite material, the laminate structure dampens these vibrations. Secondly, the integration of sensors allow to monitor process vibrati...
Article
The aim of this study is to evaluate impact of varying core hole diameters on resulting thread quality for helical thread forming. Regarding to common applications in mass production of engine casings in automotive industy, the experiments were performed in AlSi10MnMg cast alloy and thread size M6. Regarding the forming process by analysis of mecha...
Article
Full-text available
The characteristic segmented chip formation of titanium alloy Ti6Al4V leads to a periodic excitation and therefore to vibrations during the process. One way to avoid these chip formation induced vibrations is to position a counter element, the constraint, in front of the primary shear zone which suppresses the segmentation mechanism. In this paper,...
Article
Full-text available
Surface structuring offers great potential for modifying frictional properties for various applications, such as complex forming processes like sheet-bulk metal forming. The production of surface structures in micrometre range is challenging for manufacturing processes in particular when machining hard-to-cut materials like hardened tool steels. Pr...
Article
Full-text available
Hot forming processes of complex parts with small cavities demand high-performance tools made of hardened steels. Their surface can be tribologically modified in order to control the material flow for improving the mold filling of functional elements. Surface structuring here offers great potential for adjusting the frictional properties and thus c...
Article
Deep drilling with smallest diameters is used for applications such as automotive, aerospace and medicine. Especially difficult to cut materials require an efficient tool design to realize an economical production. Therefore, combined simulation methods are used in this paper to analyze the fluid behavior under consideration of the transient chip p...
Article
Full-text available
The residual stress state in the subsurface is a key element of surface integrity. It is well known to have a significant impact on a component’s properties in terms of fatigue behavior and resistance to wear and corrosion. For this reason, adjusting residual stresses during manufacturing is a major challenge in modern production engineering, to im...
Article
Full-text available
For single-lip drills with small diameters, the cutting fluid is supplied through a kidney-shaped cooling channel inside the tool. In addition to reducing friction, the cutting fluid is also important for the dissipation of heat at the cutting edge and for the chip removal. However, in previous investigations of single-lip drills, it was observed t...
Article
The surface integrity of components is decisive for their fatigue strength and is significantly influenced by applied machining processes. Particularly in drilling, the used coolant strategy affects the process stability and the surface quality produced due to its contribution to chip evacuation and the cooling and lubricating effect of the cutting...
Article
The surface integrity is crucial for the capability of machined parts; therefore, a detailed characterization of the obtained microstructure is very important for the assessment of machining processes. In this paper, the microstructure of single-lip deep drilled specimen, especially the formation of white etching layers (WEL), is considered by micr...
Article
The BTA deep hole drilling process is used to machine deep bores with a large diameter. The cutting process, consisting of the material removal by cutting edge and the surface burnishing by the guidepads influence the surface of the bore. To separate the impact of the cutting edge from that of the guidepads on the surface of the bore and the subsur...
Article
Ejector deep hole drilling is required for a variety of drilling applications with length-to-diameter-ratios larger than l/D > 10 and high quality demands, e.g. on roundness, diameter accuracy and surface quality. The ejector effect is essential for the process and decisive for a stable ejector deep hole drilling process by supplying the working zo...
Article
To machine bores with larger diameters (D > 40mm) and a length to diameter ratio greater than ten (lb/D > 10) the BTA deep hole drilling process is often used. The cutting action of the cutting edge and the burnishing of the guide pads influence the resulting surface and the subsurface zone of the machined bore. The guide pads support the BTA drill...
Chapter
Diamond impregnated tools for core drilling consist of segments in which synthetical diamonds are bounded in a metal matrix. The wear of these tools depends on the time points when active diamonds breakout and new diamonds from deeper layers of the metal matrix become active. Up to now, these time points were measured only by visual inspection at g...
Article
Full-text available
High flexibility of the micro-milling process compared to nontraditional methods has led to its growing application in manufacturing complex micro-parts with tight tolerances and high accuracies. However, difficulties such as tool deflection, size effect, and tool wear limit the application of micro-milling. In this regard, the role of laser-assist...
Article
Additional to the conventional requirements for the component quality, the residual stress state of the sub-surface is becoming increasingly important as it affects the fatigue and wear behaviour of the component. First results indicate that micromilling allows the induction of high residual compressive stresses to increase the component's service...
Article
Full-text available
Anchorage to concrete is a recurring application in construction. For such applications, bonded anchors, formed by means of a polymer adhesive injection into a borehole, are a widely used product due to their flexibility in regards to the construction logistics and positioning of the attached element as well as high load capacities. At the same tim...
Article
Full-text available
New manufacturing technologies, such as Sheet-Bulk Metal Forming, are facing the challenges of highly stressed tool surfaces which are limiting their service life. For this reason, the load-adapted design of surfaces and the subsurface region as well as the application of wear-resistant coatings for forming dies and molds made of high-speed steel h...
Article
High interstitial austenitic stainless CrMn steels are characterised by significantly increased work hardening ability and strength compared with conventional CrNi austenites, yet maintaining very high ductility and toughness. The machining of high interstitial CrMnCN steels is challenging in terms of process stability and economic efficiency. In t...
Article
Full-text available
Offshore installations, e.g., offshore wind turbines and pipelines, are exposed to various mechanical loads due to wind or waves and corrosive loads such as seawater or mist. ZnAlbased thermal sprayed coatings, often in conjunction with organic coatings, provide sufficient corrosion protection and are well established for applications in marine env...
Article
Dispersed short steel fibres can be used as an addition to the concrete matrix as reinforcement to improve the material's macroscopic characteristics such as tensile strength, ductility and toughness. On the other hand, fibres may lead to negative effects in terms of constructability. For post-installed anchors, the tensile performance of the concr...
Article
When micro-single-lip deep hole drilling the efficiency of the cutting fluid supply cannot be investigated experimentally due to the inaccessibility of the cutting zone. For this reason, this paper examines the cutting fluid behavior, taking into account the chip formation and the transient chip position, with the help of various combined simulatio...
Article
Full-text available
Structural elements for applications in maritime environments, especially offshore installations, are subjected to various stresses, such as mechanical loads caused by wind or waves and corrosive attacks, e.g., by seawater, mist and weather. Thermally sprayed ZnAl coatings are often used for maritime applications, mainly due to good corrosion prote...
Article
Magnetic abrasive finishing (MAF) can be used on CNC machine tools as a final machining step to finish workpieces after the milling process. This paper presents a new tool system for the magnetic abrasive finishing of flat surfaces on traditional CNC machine tools using permanent magnets and a paramagnetic adapter without magnetizing the spindle. F...
Article
In BTA deep hole drilling straightness deviation of the bore is a very important quality criteria. The avoidance of straightness deviation is not possible due to the many influencing variables. Currently used methods for compensation require significant additional time, as they either require the interruption of the drilling process, or require an...
Article
Full-text available
An experimental analysis regarding the distribution of the cutting fluid is very difficult due to the inaccessibility of the contact zone within the bore hole. Therefore, suitable simulation models are necessary to evaluate new tool designs and optimize drilling processes. In this paper the coolant distribution during helical deep hole drilling is...
Article
Kurzfassung In der vorliegenden Arbeit wird der Einfluss der Prozessparameter auf die Eigenspannungsausbildung bei der Drehbearbeitung eines Bauteils mit einer funktional gradierten Eigenschaftsverteilung untersucht. Es handelt sich um eine in einem thermo-mechanischen Umformprozess hergestellte Flanschwelle aus dem Werkstoff 51CrV4, bei der eine c...
Article
Um thermische Spritzschichten mit erhöhter Haftfestigkeit zu realisieren, erfolgte am Institut für Spanende Fertigung (ISF) der Technischen Universität Dortmund und dem Institut für Werkstoffkunde (IW) der Leibniz Universität Hannover die Entwicklung einer innovativen Verfahrenskombination. Darauf aufbauend wurde untersucht, ob die Schichteigenscha...
Article
Full-text available
A stainless precipitation hardening steel has been qualified for powder bed fusion of metals using a laser beam. The mechanical and microstructural properties of additively manufactured samples have been thoroughly investigated and compared to samples of the very same material made by means of ingot casting. Additive manufacturing is feasible and c...
Article
Full-text available
Deep hole drilling processes for high-alloyed materials are characterised by worn guide pads and chatter vibrations. In order to increase feed rates, process stability and bore quality in STS deep hole drilling, various investigations were carried out with adjustments to the tool. First, a new process chain for the production of tribologically opti...
Article
Full-text available
The wear resistance of coated cutting tools depends to a large extent on adhesion of applied PVD coatings. The adjustment of the surface roughness as well as the residual stresses of the sub-surface of the substrate thus represents a decisive step in tool manufacturing. For this reason, the conditioning of the surface and sub-surface constitution o...
Article
Full-text available
Based on the process design, presented in part 1, the impact of feed and cutting speed on residual stress, microstructure and microhardness in the subsurface zone of the bores is analyzed. The formation of residual stresses is found to depend significantly on the selection of cutting parameters. When using high feed rates, white etching layers (WEL...
Article
Die Verfahrenskombination aus Laserpilotieren und Einlippentiefbohren ist ein vielversprechender Ansatz, die Flexibilität bei Tiefbohrbearbeitungen signifikant zu steigern. Mithilfe des Lasersystems ist es dabei möglich, verschleißfrei Pilotbohrungen auf schrägen, gekrümmten oder sogar randschichtgehärteten Bauteilen zu erzeugen.
Article
ZnAl-based coatings are used as corrosion protection for offshore application, e.g., offshore wind turbines. These applications are subjected to superimposed mechanical and corrosive stresses, e.g., wind, tide, seawater and mist. Thermally sprayed coatings processed by twin wire arc spray process and the mechanical post-treatment process machine ha...
Article
(Mikro-) Magnetische Prüfsysteme werden zur schnellen und zerstörungsfreien Charakterisierung von Oberflächenrandzonen BTA-tiefgebohrter Komponenten eingesetzt. Zur Erhöhung der Robustheit der Prüfmethodik erfolgen Analysen der Störgrößen sowie Validierungsmessungen mit verschiedenen Prüfsystemen und Sensoriken. Die Untersuchungen sind Teil der Ent...
Article
Full-text available
In the twin wire arc spraying (TWAS) process, it is common to use compressed air as atomizing gas. Nitrogen or argon also are used to reduce oxidation and improve coating performance. The heat required to melt the feedstock material depends on the electrical conductivity of the wires used and the ionization energy of both the feedstock material and...
Article
Full-text available
Grinding wheels are usually manufactured by powder metallurgical processes, i.e., by molding and sintering. Since this requires the production of special molds and the sintering is typically carried out in a continuous furnace, this process is time-consuming and cost-intensive. Therefore, it is only worthwhile for medium and large batches. Another...
Article
Full-text available
Hot work tool steels (HWS) are widely used for high performance components as dies and molds in hot forging processes, where extreme process-related mechanical and thermal loads limit tool life. With the functionalizing and modification of tool surfaces with tailored surfaces, a promising approach is given to provide material flow control resulting...
Article
Full-text available
The fatigue behavior of components made of quenched and tempered steel alloys is of elementary importance, especially in the automotive industry. To a great extent, the components’ fatigue strength is influenced by the surface integrity properties. For machined components, the generated surface is often exposed to the highest thermomechanical loads...
Conference Paper
Full-text available
The technology of front face flow drilling makes it possible to extend the material thickness of thin-walled workpieces. By a following tapping process, threads with high mechanical strength can be manufactured in the hardened deformation zone. In addition to the process design for the formation of the core hole, the process strategy for thread for...
Article
For new developments of manufacturing processes in which cooling lubricants are used, the design of cutting tools plays an important role in achieving effective coolant flow behaviour. In this work, new bottle boring systems for profiling and finishing the ground and the wall of a bore, as well as a novel bottle boring system for the machining of n...
Article
Industrielle Bohrprozesse sind insbesondere im Rahmen der anspruchsvollen Bearbeitung von Hochleistungswerkstoffen mit limitierter Werkzeugstandzeit, Bauteilgüte und allgemein herabgesetzter Produktivität verbunden. Der Einsatz von Kühlschmierstoffen(KSS) ist somit essenziell, um die Wirkpartner im Prozess zu kühlen, die Kontaktzonen zu schmieren u...
Article
Full-text available
By using modern technologies to produce detachable joints in lightweight components, it is possible to reduce material consumption and manufacturing times. By front face flow drilling of lightweight cast materials, expanded bore walls are formed into thin-walled profiles, which are used as core holes for internal threads. The flow drilling process...
Article
Full-text available
Numerical simulation of metal cutting with rigorous experimental validation is a profitable approach that facilitates process optimization and better productivity. In this work, we apply the Smoothed Particle Hydrodynamics (SPH) and Finite Element Method (FEM) to simulate the chip formation process within a thermo-mechanically coupled framework. A...
Article
Nickel-base super-alloys such as Inconel 718 are used for demanding applications in the industry. Their superior corrosion resistance and mechanical properties, especially under high heat and pressure, make them very attractive for highly stressed components. In contrast, their low thermal conductivity, work hardening tendency and high strength imp...
Article
Full-text available
Structural elements of offshore facilities, e.g., offshore wind turbines, are subject to static and dynamic mechanical and environmental loads, for example, from wind, waves, and corrosive media. Protective coatings such as thermal sprayed ZnAl coatings are often used for protection, mainly against corrosive stresses. The Machine Hammer Peening (MH...
Article
Full-text available
Magnetic abrasive finishing (MAF) shows a high potential for use on computerized numerical control (CNC) machine tools as a standard tool to polish workpieces directly after the milling process. This paper presents a new MAF tool with a single, large permanent magnet and a novel top cover structure for finishing the plain ferromagnetic workpieces....
Article
Toolpath represented by linear segments leads to tangency discontinuity between blocks, which results in fluctuation of feedrate and reduction of machining efficiency and quality. To eliminate these unwanted external factors, optimal corner smoothing operation is essential for CNC systems to achieve a smooth toolpath. This work proposes a corner sm...
Article
Full-text available
The machining of free-formed surfaces, e.g., dies or moulds, is often affected by tool vibrations, which can affect the quality of the workpiece surface. Furthermore, in 5-axis milling, the dynamic properties of the system consisting of the tool, spindle and machine tool can vary depending on the tool pose. In this paper, a simulation-based methodo...
Article
In this study the important aspects of cutting fluid distribution and the chip evacuation during micro twist deep-hole drilling are investigated using 3D multi-physics simulation methods. A coupled particle simulation is performed to analyze the chip transport by combining Smoothed Particle Hydrodynamics and the Discrete Element Method. Therefore,...
Chapter
Diamond impregnated segments are used for the machining of concrete. In current projects, the diamonds are no longer inserted statistically but deterministically. The positioning of the diamonds has advantages in terms of increased performance, lower raw material requirements or improved wear. This paper aims towards the lifetime and the wear of di...
Chapter
BTA deep hole drilling is used to produce bore holes with high bore hole qualities and high length-to-diameter ratios. The tool system consists of a drill head and a drill tube. However, the length of the drill tube required to achieve high drilling depths leads to an increased tendency of the tool system to vibrate. The strong torsional vibrations...
Chapter
The efficient execution of demanding deep hole drilling operations represents a major challenge for manufacturing companies. The ejector method makes the advantages of deep hole drilling, such as high material removal rate and bore quality, usable for the industry on conventional machining centers. Thus, no expensive deep hole drilling machine with...
Article
This study investigates the influence of the pre-drilling diameter on hardness and tensile failure of the formed internal threads (M6), manufactured perpendicular to the profile thickness of thin-walled AZ91 magnesium casting alloys. Previous investigations have shown that introducing a pre-drilling before friction drilling prevents the failure of...
Article
Full-text available
In the past few decades, there has been considerable advancement in developing and testing structured and textured cutting tools for different machining operations. This paper not only presents a review of the state-of-the-art in manufacturing processes to structure and texture surfaces of cutting tools for machining applications but also identifie...
Article
Full-text available
The occurrence of chatter vibrations in 5-axis milling processes is a common problem and can result in part failure, surface defects and increased wear of the cutting tool and the machine tool. In order to prevent process vibrations, machining processes can be optimized by utilizing geometric physically-based simulation systems. Since the modal par...
Article
Inconel 718 as one of the most common nickel-base alloys is mainly characterized by its high-temperature strength. Thus, in particular drilling is subject to high tool wear due to high thermomechanical loads on the cutting edges. To reduce those effects an alternative process design of discontinuous drilling was developed which contains a periodica...
Article
The thermomechanical load on the workpiece surface during the machining process strongly influences its surface integrity and the resulting fatigue strength of the components. In single-lip drilling, the measurement of the mechanical load using dynamometers is well established, but the thermal interactions between the tool and the workpiece materia...
Conference Paper
Increasing requirements and a high degree of freedom in design increasingly demand the manufacturing of bore holes with small diameters and high length-to-diameter ratios on complex shaped surfaces. Injection nozzles, medical tools and implants, cooling holes or oil channels are just a few examples. Unlike mechanical drilling tools, the laser beam...
Article
When machining the titanium alloy Ti6Al4V, segmented chip formation is a major challenge as it leads to chatter-vibrations of the tool-machine-system. In this paper a counter element to suppress segmentation, the constraint, is designed by simulations. Therefore, the segmented chip formation of Ti6Al4V has been modelled in a finite element simulati...
Conference Paper
Metal structures in offshore facilities are usually protected from corrosion using Zn-Al coatings even though they are subjected to collective stress conditions. This paper evaluates a post-treatment called machine hammer peening and its effect on surface finish, induced residual stresses, and near-surface microstructure of thermally sprayed ZnAl4...
Conference Paper
Grinding wheels are usually manufactured by powder metallurgical processes, i.e. by moulding and sintering. Since this requires the production of special moulds and the sintering is typically carried out in a continuous furnace, this process is time-consuming and cost-intensive. Therefore, it is only worthwhile for medium and large batches. Another...
Article
Full-text available
Internal traverse grinding (ITG) using electroplated cBN tools in high-speed grinding conditions is a highly efficient manufacturing process for bore machining in a single axial stroke. However, process control is difficult. Due to the axial direction of feed, changes in process normal force and thus radial deflection of the tool and workpiece spin...
Article
Full-text available
The increasing demand for high-performance components is leading to a greater use of advanced alloys such as DA718, which is, e.g., used in engine parts due to its high-temperature strength. The strict quality requirements pose major challenges for the machining of engine components for aircrafts. Quality deviations along the value chain can lead t...
Article
Free-formed surfaces, e.g. of dies, can be finished using 5-axis milling processes. Due to the varying tool-engagement situations and the dynamic behavior of the tool-spindle-machine system, the avoidance of chatter vibrations is challenging for these processes. Since the dynamic behavior depends on the position of the axes, the process stability c...