Enabling advanced functionalities of Diamond and other ultra-hard materials by Integrated Pulsed Laser Ablation Technologies

Summary
Diamond and other ultra-hard materials possess outstanding mechanical, wear and thermal properties that make them attractive to manufacture a wide range of high value-added products such as high-performance, smart tools. However, due to the extreme properties of this group of materials, efficient and precise generation of complex 3D freeform geometries and structures to meet the needs for a further development of high-performance tools is still a challenge. DIPLAT addresses the need for an efficient, precise and flexible processing technology for ultra-hard materials in tooling applications, in order to fully exploit the potential of these materials. By smartly utilizing the advantages of high brilliance short and ultra-short pulsed lasers, a tooling technology based on 3D Pulsed Laser Ablation (PLA) will be developed and demonstrated for various industrial applications. DIPLAT will introduce new technology platform for producing ultra-hard tools with enhanced functionality, outstanding machining performance and superior lift-time. In this regard, DIPLAT fosters the following four main scientific and technological objectives: (1) Design functional surfaces (with controlled micro geometries) on diamond and other ultra-hard materials to enable enhanced functionality for tooling applications; (2) Study and development of advanced 3D processing strategies for structuring/conditioning of ultra-hard tool surfaces and superabrasive grain layers by Pulsed Laser Ablation; (3) Develop and implement a novel multi-axis control concept and a model-based CAM software support module to enable optimized 3D pulsed laser processing; (4) Fabrication of various novel prototype tools made of ultra-hard materials and demonstration of their superior performance and functionality in challenging industrial applications. DIPLAT will lead to a technological breakthrough that will push European manufacturing industries to the cutting edge of high-performance machining and tooling technology.
More information
Web resources: http://www.fp7-diplat.eu/
https://cordis.europa.eu/project/rcn/105911/factsheet/en
Start date: 15-01-2013
End date: 14-07-2016
Total budget - Public funding: 5 108 607,00 Euro - 3 199 685,00 Euro
Call topic: Innovative technologies for casting, material removing and forming processes (FoF.NMP.2012-7)
Cordis data

Original description

Diamond and other ultra-hard materials possess outstanding mechanical, wear and thermal properties that make them attractive to manufacture a wide range of high value-added products such as high-performance, smart tools. However, due to the extreme properties of this group of materials, efficient and precise generation of complex 3D freeform geometries and structures to meet the needs for a further development of high-performance tools is still a challenge. DIPLAT addresses the need for an efficient, precise and flexible processing technology for ultra-hard materials in tooling applications, in order to fully exploit the potential of these materials. By smartly utilizing the advantages of high brilliance short and ultra-short pulsed lasers, a tooling technology based on 3D Pulsed Laser Ablation (PLA) will be developed and demonstrated for various industrial applications. DIPLAT will introduce new technology platform for producing ultra-hard tools with enhanced functionality, outstanding machining performance and superior lift-time. In this regard, DIPLAT fosters the following four main scientific and technological objectives: (1) Design functional surfaces (with controlled micro geometries) on diamond and other ultra-hard materials to enable enhanced functionality for tooling applications; (2) Study and development of advanced 3D processing strategies for structuring/conditioning of ultra-hard tool surfaces and superabrasive grain layers by Pulsed Laser Ablation; (3) Develop and implement a novel multi-axis control concept and a model-based CAM software support module to enable optimized 3D pulsed laser processing; (4) Fabrication of various novel prototype tools made of ultra-hard materials and demonstration of their superior performance and functionality in challenging industrial applications. DIPLAT will lead to a technological breakthrough that will push European manufacturing industries to the cutting edge of high-performance machining and tooling technology.

Status

ONG

Call topic

FoF.NMP.2012-7

Update Date

07-11-2021
Images
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Location

Relevant items: View structured details below

Economic sustainability Circular economy Social sustainability Occupational safety and health Environmental sustainability
Reducing the consumption of water and other process resource... Reducing emissions in manufacturing processes Material efficiency Co-evolution of products-processes-production systems (‘indu... Reduction of waste (in %)
    Comment: The wear-free nature of laser processes allow highly precise and robust manufacturing processes. The diamond and CBN tool produced in DIPLAT exhibit a maximum tool lifetime, which makes them most suitable for high precision processes and high levels of automation while reducing the amount tool waste.
      Comment: DIPLAT tools are consist of the newest polycrystalline diamond and cubic boron nitride composites. The laser processed developed within DIPLAT allow the efficient application of these difficult to machine materials. DIPLAT tools are designed for the efficient processing of CFRP and other composite materials in the aerospace industry.
        Comment: Laser manufactruing is a completely wear-free process. The waste of conventional processes, such as grinding (tools, coolant, lubricant) and spark erosion (electrodes, dieletric) is completely eliminated.
      Comment: The laser processes developed in DIPLAT are highly energy efficient compared to conventional diamond processing technologies. Furthermore, they require no consumables such as processing fluids, electrodes, grinding tools, ... The tools produced in DIPLAT facilitate "dry" cutting processes and replace grinding processes. As the supply of cooling lubricants consumes a high percenatge of the energy in these conventional processes, this raises the resource efficieny of all products manufactured by these tools.

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Manufacturing the products of the future Novel materials Complex structures, geometries and scale
Resource efficient, sustainable products Domain 2: Adaptive and smart manufacturing systems
      Comment: The laser processes developed in DIPLAT enable the machining of compex geometries on different tooling applications: helical milling and drilling tools, micro-tools, clearance on stochastic abrasive surface
      Comment: DIPLAT tools are consist of the newest polycrystalline diamond and cubic boron nitride composites. The laser processed developed within DIPLAT allow the efficient application of these difficult to machine materials. DIPLAT tools are designed for the efficient processing of CFRP and other composite materials in the aerospace industry.
      Comment: The laser processes developed in DIPLAT are highly energy efficient compared to conventional diamond processing technologies. Furthermore, they require no consumables such as processing fluids, electrodes, grinding tools, ... The tools produced in DIPLAT facilitate "dry" cutting processes and replace grinding processes. As the supply of cooling lubricants consumes a high percenatge of the energy in these conventional processes, this raises the resource efficieny of all products manufactured by these tools.

Relevant items: View structured details below

Advanced material processing technologies Photonics-based materials processing technologies Mechatronics and robotics technologies Control technologies Advanced and ubiquitous human machine interaction
Advanced materials in manufacturing systems Information and communication technologies ICT solutions for modelling and simulation tools Modelling and simulation methods of manufacturing processes ...