Tobias Surmann

Tobias Surmann
Premium Aerotec · NC-Programming

Dr.-Ing., Dipl.-Inform.

About

51
Publications
3,201
Reads
How we measure 'reads'
A 'read' is counted each time someone views a publication summary (such as the title, abstract, and list of authors), clicks on a figure, or views or downloads the full-text. Learn more
760
Citations
Citations since 2017
1 Research Item
292 Citations
201720182019202020212022202301020304050
201720182019202020212022202301020304050
201720182019202020212022202301020304050
201720182019202020212022202301020304050
Additional affiliations
August 2000 - January 2013
Technische Universität Dortmund
Position
  • Head of Department

Publications

Publications (51)
Article
The use of tools with chamfered cutting edges is an essential part of high performance cutting (HPC) as a rough milling process strategy for manufacturing structural components in the aerospace industry. Due to an interaction between the chamfer and the undulated workpiece surface, tool vibrations can be damped allowing high depths of cut without t...
Article
Full-text available
For the production of large structural components, the NC-milling process is often run with minimum quantity lubrication only. Additionally, most of the raw material will be removed by using process parameters that lead to a significant generation of heat. To guarantee error-free products, the thermally induced deformation has to be taken into acco...
Article
Oscillator models provide an efficient approach for simulating the dynamic behaviour of the machine, tool, or workpiece. In their application, however, these models are usually limited to describing the vibration behaviour at one specific position since they do not contain any information about the structure of the machine tool or the workpiece. Ad...
Article
In production engineering, there are several applications where the geometry of a designed workpiece has to be modified, e.g., optimization of forming tools during springback compensation in sheet metal forming. In general, the modified shape of the workpiece is given as a mesh and has to be converted to a parametric representation by surface recon...
Article
Full-text available
The manufacturing of medical implants and the micro die- and mould-machining are typical fields of application for five-axis micromilling. The machined materials diversify from NiTi shape memory alloys to hardened steels. First experimental results reveal a strong dependency of the machinability of the aforementioned engineering materials on cutter...
Article
The unprecedented success of the iterative closest point (ICP) method for registration in geometry processing and related fields can be attributed to its efficiency, robustness, and wide spectrum of applications. Its use is however quite limited as soon as the objects to be registered arise from each other by a transformation significantly differen...
Article
Nowadays, many manufacturing processes require the machining of complex forms with a high aspect ratio or cavities. Tools with a long overhang length are a common method to meet these requirements. Typical examples for this are boring bars for bore-turning and the milling with very long cutters. These tools tend to vibrate strongly due to their sle...
Article
In most cases the simulation of temperature distributions in machined workpieces is carried out by moving a heat source along a predefined workpiece model within a commercial FEM-system. For performance reasons, the material removal is often neglected or performed by removing small predefined parts of the workpiece. Furthermore, the heat source oft...
Article
In this paper, a novel method for the modeling and characterization of surface structures is presented. The method is based on the nonparametric statistical modeling of the surface structure, represented as a two dimensional field. Using a sample of a surface structure in question, the model reproduces the structure of the surface and estimates the...
Article
Full-text available
In production engineering, the process of reverse engineering often requires modifications of CAD/CAM data. In general, CAD surfaces are modified according to a set of discrete displacement vectors. For this purpose, smoothing space-deformation techniques like free-form deformation (FFD) can be used. We present a B-spline-based adaptive FFD, which...
Article
Workpiece vibrations have a significant influence on the machining process and on the quality of the resulting workpiece surface, particularly when milling thin-walled components. In this paper a simulation system, consisting of an FE model of the workpiece coupled with a geometric milling simulation for computing regenerative workpiece vibrations...
Article
In this paper a new approach for manufacturing modified workpieces by milling is presented. In course of product development, several optimization iterations are often required, in which the shape of the workpiece is modified. Conventional method for manufacturing modified workpieces includes a time-consuming and error-prone step of reverse enginee...
Article
Micromilling of NiTi shape-memory alloys (SMA) places high demands on tools and machining processes. NiTi is classified as a difficult-to-cut material due to its special properties. A new approach to machine NiTi with higher process flexibility is the application of ball nose cutters in micromilling processes. The article presents the latest result...
Article
Tool vibrations have a significant influence on the surface quality with respect to surface location error and roughness. Even chatter-free milling processes can produce a high surface location error since chatter-free does not necessarily mean vibration-free. This article describes a geometric model for predicting the surface formation resulting f...
Article
During milling—especially of thin-walled components—the dynamic behavior of the workpiece-tool-machine-system influences the milling process and particularly the quality of the resulting workpiece surface. This article focuses on the presentation of a simulation concept for predicting regenerative workpiece vibrations, which combines a finite eleme...
Article
The detection of undesirable vibrations in milling operations is an important task for the manufacturing engineer. While monitoring the frequency spectra is usually an efficient approach for chatter detection, since these spectra typically have a clear and systematic structure, we show in this paper that the stability of the cutting process cannot...
Article
Full-text available
Lightweight extrusion profiles with reinforcement elements are promising news in the domain of lightweight construction. The machining of them suffers from several problems: Aside from the question of choosing a suitable tool, feed rate, and milling strategy, an excessive rise in temperature could lead to stress and even a distortion due to the dif...
Article
When milling with tools of a high length to diameter ratio, there is often a non negligible runout. Since those tools tend towards chatter because of their low stiffness, the effect of runout on the dynamic behavior of the tool must be considered. Runout adds an additional dynamic component to the tool vibration and thus to the dynamicly changing c...
Article
In order to simulate belt grinding processes (e.g. for process planning or path planning) one usually needs information about the contact zone and contact forces. Typically, an unacceptable computational effort is required for good simulation results, since these contact problems are usually of a nonlinear nature. In this paper, the application of...
Article
Kurzfassung Werkzeug- und Maschinenschwingungen haben nicht nur einen großen Einfluss auf das Verschleißverhalten der Werkzeuge, sondern auch auf die resultierende Oberflächenqualität. In diesem Beitrag sind die Auswirkungen von selbsterregten Werkzeugschwingungen auf die vom Werkzeug erzeugten Oberflächen bezüglich Mikrostrukturen und Konturabweic...
Article
Vibrations of tools and machines affect the toolwear as well as the surface quality. This paper describes the influence of self induced tool vibrations on the surface in respect to microstructures and contour deviations depending on the rotation frequency of slender cylindric milling tools in face milling operations. The analysis of the occurring e...
Article
This paper presents a simulation system, which is able to model engagement conditions as a syntactical geometric model along arbitrary NC-programs. This modeling approach allows the feedback of tool deflections into the model of the chip form, which enables the simulation of regenerative tool vibrations along changing engagement conditions. Methods...
Article
Detection of undesired machine tool vibrations during milling operations is an important task for manufacturing engineers. Monitoring of frequency spectra is an efficient tool of chatter detection since these spectra usually have a clear, systematic structure. However, for some special cases, stability of the cutting process cannot be assessed base...
Article
This paper presents a methodology and algorithms for analytically formulating the swept profiles and generating topological valid swept volume of five-axis tool motions for NC simulation. For the problem of NC simulation, by using envelope theory and swept volume generation, a canonical mathematic description to formulate the swept profiles is addr...
Chapter
Full-text available
Evolutionary algorithms are a class of direct search methods. They can be used whenever classical optimization methods do not yield satisfactory results. In the following we discuss the design of problem-specific evolutionary algorithms. We present a technique for the systematic integration of domain knowledge. Surface reconstruction by means of ev...
Conference Paper
The idea of multi-dexel volumes is to use more than one dexel volume for representation of a solid. In this manner the difficulty of unequal sampling densities dependent on the slope of the surface relative to the direction of the dexels is overcome. We present algorithms for orthogonal 3-dexel volumes, which concern on-line sculpting by erasing an...
Chapter
Full-text available
Evolutionary algorithms are a class of direct search methods. They can be used whenever classical optimization methods do not yield satisfactory results. In the following we discuss the design of problem-specific evolutionary algorithms. We present a technique for the systematic integration of domain knowledge. Surface reconstruction by means of ev...
Article
Kurzfassung Die Simulation von Zerspanprozessen erfordert Modelle für das Werkzeug und Werkstück, die den jeweiligen Genauigkeitsanforderungen an die Simulationsergebnisse gerecht werden. Für die Fräs- und Schleifbearbeitung von Freiformflächen haben sich zwei Modellierungsansätze, das Multidexelvolumenmodell und das Versatzvektorfeld, als geeignet...
Article
For simulation of machining processes. The simulation of machining processes requires models for the tool and workpiece that are up to the respective accuracy requirements on the simulation results. For the milling and grinding of free-form surfaces, two modelling approaches, the multipixel volume model and the offset vector field, have proven suit...
Conference Paper
The task of surface reconstruction is to find a mathematical representation of a surface which is given only by a set of discrete sampling points. The mathematical description in the computer allows to save or transfer the geometric data via internet, to manipulate (e.g. for aerodynamic or design specific reasons) or to optimize the machining of th...
Article
Full-text available
The aim of evolutionary surface reconstruction is to find mathematical descriptions of surfaces of physical objects. These objects are represented only by discrete sampling points. The reconstructions have to render the original shape of the objects as realistic as possible. Therefore, complex discrete approximation problems must be solved. In orde...
Article
Full-text available
In addition to the prediction of whether a milling process is free of chatter or not, the resulting surface quality is of importance. This paper presents geometric models of the machined workpiece in order to predict the surface microstructures of the peripherally milled flank structures as well as the surface resulting from the slab milling proces...
Article
Full-text available
In mechanical engineering, especially in metal sheet forming, the compensation of form errors caused by springback is usually handled by numeric simulation or re-peated refinement of a workpiece. But since the simulation of springback can gener-ally only approximate the real process, costly refinements cannot be avoided. Thus, different means of de...
Article
Kurzfassung Werkzeug-und Maschinenschwingungen haben nicht nur einen großen Einfluss auf das Verschleißverhalten der Werkzeuge, sondern auch auf die resultierende Oberflächenqualität. In diesem Beitrag sind die Auswirkungen von selbsterregten Werkzeugschwingungen auf die vom Werkzeug erzeugten Oberflächen bezüglich Mikrostrukturen und Kontur-abweic...

Network

Cited By

Projects

Projects (2)
Archived project
Archived project