Institute of Machine Tools and ManufacturingOpen OpportunitiesCutting-edge tools play a pivotal role in manufacturing processes, enduring wear and damage while consistently producing series of components. Maintaining an optimal cutting-edge geometry is crucial to uphold the quality of finished products over time. Additionally, sustaining the micro-geometry of the cutting edge is key to enhancing the lifespan of the tool and ensuring top-notch cutting performance. Profin addresses this challenge with Flakkotting, a novel surface finishing process designed explicitly to create and preserve the required micro-geometry.
The aim of this thesis is to develop the understanding of Flakkotting process and develop prediction model for process parameters for a given micro-geometry. The dynamics of flakkotting tools on Tungsten Carbide drills and cutting-edge inserts will be studied with varying parameters using high-speed imaging and microscopic analysis. Using the parameter data and evaluated workpieces, machine learning (ML) models will be developed for prediction of micro-geometry features and optimization of process based on the required micro-geometry. - Computer Vision, Image Processing, Manufacturing Engineering, Mechanical Engineering, Pattern Recognition, Statistics
- Bachelor Thesis, Internship, Master Thesis
| This Master's thesis focuses on the experimental determination of material properties for Ti6Al4V, essential for the numerical simulation of machining processes. The work involves preparing various samples, conducting flow curve tests, damage behavior analyses, and anisotropy assessments. Additionally, EBSD analysis, hardness measurements, and potentially chemical analyses will be performed. The results will be used to validate machining simulations using SPH/FEM, comparing process forces and chip formation. - Mechanical and Industrial Engineering
- ETH Zurich (ETHZ), Master Thesis
| This Master's thesis focuses on the experimental determination of material properties for stainless steel, essential for the numerical simulation of machining processes. The work involves preparing various samples, conducting flow curve tests, damage behavior analyses, and anisotropy assessments. Additionally, EBSD analysis, hardness measurements, and potentially chemical analyses will be performed. The results will be used to validate machining simulations using SPH/FEM, comparing process forces and chip formation. - Mechanical Engineering
- ETH Zurich (ETHZ), Master Thesis
| Gears are the backbone of the aircraft transmission systems, facilitating critical power transfer and speed adjustments for various components. Their flawless operation is the key to the seamless flight of lightning-fast fighter jets, commercial airliners, and agile helicopters.
As the demand for precise, robust, and dependable gears continues to rise, addressing production bottlenecks becomes increasingly crucial in meeting aviation's evolving needs. A significant contributor to these bottlenecks is the grinding operation, the final step in production. In the pursuit of achieving higher production efficiency by pushing the limits of process parameters, grinding burns often appear on the workpiece surface. These grinding burns are undesirable. They occur due to excess heat accumulation which impacts residual stresses and metallurgical structures, potentially leading to component cracks and failures. The rejection of such workpieces wastes time and resources, ultimately diminishing production efficiency.
The primary focus of this thesis is the early detection of grinding burns within the manufacturing process, achieved through the utilization of acoustic emission and current sensors in combination with critical process parameters. A mathematical model will be developed based on machine learning modeling techniques combining the sensors data, process parameters and evaluated surface quality. The objectives are prediction of grinding burn, and subsequently, optimization of the grinding process for higher productivity. - Interdisciplinary Engineering, Mechanical Engineering, Signal Processing, Statistics
- Bachelor Thesis, Internship, Master Thesis, Semester Project
| Walking has been proven to create the best sense of presence while exploring
virtual environments. However, walking in virtual environments comes with the
constraint that the virtual and the physical space must have the same
dimensions. This limitation restricts the size of the virtual spaces. Various techniques have been developed to overcome this issue, such as RDW and impossible spaces. Although significant progress has been made with these methods, exploring large virtual environments can still lead the user to reach the boundaries of the physical space. Therefore, a safety mechanism is needed to prevent the user from colliding with the walls. The most popular safety mechanism is having resets, which are messages displayed to the user asking them to stop and perform a certain action that turns them away from the wall before continuing the exploration. However, resets reduce immersion and thus should be avoided as much as possible. - Computer-Human Interaction
- Bachelor Thesis, ETH Zurich (ETHZ), Semester Project
| see attachment - Engineering and Technology
- Other specific labels
| The process forces during machining with abrasives is critical for efficiency of the process and quality of the final product. The forces arise from different mechanisms like sliding, plowing and cutting. Although material removal occurs mostly by chip formation, a considerable portion of grinding energy goes to sliding between workpiece and dulled abrasive particles. This project aims to create a sliding force model to accurately predict forces with changing contact conditions in an abrasive process simulation. - Manufacturing Engineering, Mechanical Engineering
- Bachelor Thesis, Semester Project
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