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)
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      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.
    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: 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.
        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 close ccoperation of RTD-performers, technology holders and end-users in the DIPLAT project leads to a simulateneous development of manufacturing processes, manfacturing devices and products, leading to frequent adaptions of all three elements to benefit the efficiency of the collective solution.