Metal Manufacturing Technologies

The research field Metal Manufacturing Technologies concerns the transfer of technology for industrial application as one of its main tasks. Based on the Technology Readiness Level (TRL), we mainly focus on the levels TRL 3 to TRL 7.

Core competencies

Material selection
Machining processes (milling, turning, grinding,...)
Additive manufacturing (metals)
Laser processing (laser welding, laser cutting, laser structuring,...)
Coating
Clamping system development
Tool development
Simulation (FEM, Simulink, ....)
Machine tool development
Further manufacturing process developments
Material analysis (microscopy, microstructure and damage analysis, SEM images)
Process and tool engineering
Material and component testing
Material data determination
Training seminars for industry

Equipment

Additive manufacturing of metals

Hybrid machine - ELB SmartLine N10 KGT 840D
including: Laser metal deposition LMD - HMT
5-axis machining – Grinding and milling
Fused Filament Fabrication FFF - Markforged Metal X

Machining

Turning milling - DMG Mori CTX alpha 500
5-axis milling - DMU 60 mono block
3-axis milling - GF Mikron VCP 600

Heat treatment

Nabertherm N31/H (up to 1280°C)
Nabertherm NA 30/65 (up to 650°C)

Surface treatment and analysis

Water jet Finishing / Polishing - Surfast 400HP
Sandblasting - Sablux Leandblast 140s
Roughness Measurement and Form tracer - Mahr MahrSurf DU130

Ultrasonic

Ultrasonic system to different assist manufacturing technologies (excitation from 19kHz - 30kHz with various Boosters and Sonotrods)

Residual stresses

Residual stresses Measurement with Bore Hole Method (SINT MTS300 Restan)

Force measurement

Dynamometer - Kistler Type 9255C (-10kN - 60kN)
Dynamometer - Kistler Type 9129AA (-10kN - 10kN)

Various possibilities for material testing

Metallography
Fatigue test
Notched bar impact testing
Hardness measurement
Tensile/compression test
REM-EDX; CT, TGA, DSC; FT-IR;

Component testing

Microstructure and damage analysis
Non-destructive ultrasonic testing

Videos

LMD hybrid machine

Demonstration of the hybrid machine at IWK, which combines the manufacturing methods CNC profile grinding, laser metal deposition and high speed milling. 5-axes can be controlled for the production of complex workpieces. Additively manufactured workpieces are machined (grinding or milling) on a single clamping of the same machine.

Technical papers

Referee International Journal papers

2022

Metallbeschichtung von Wolframkarbid auf CK45
Rabiey, M., Würsten, P., Senne, L., Urban, L.: Metallbeschichtung von Wolframkarbid auf CK45, KunststoffXtra 3-4/2022, S. 16-19

2019

LMD bringt entscheidende Vorteile
Rabiey, M.: LMD bringt entscheidende Vorteile, KunststoffXtra 7-8/2019, S. 11-13

German Journal papers

2013

Transchel, R.; Dold, C.; Rabiey, M.: F. Kuster, K. Wegener: „Einfluss lasertouchierter Diamantabrichtwerkzeuge auf das Zerspanungsverhalten von Siliziumcarbid, Jahrbuch Schleifen, Honen, Läppen und Polieren, 2013 in print

Conference papers with peer reviewing

2011

Rabiey, M.; Walter, C.; Kuster, F.; Stirnimann, J.; Pude, F.; Wegener, K.: „ A comparative study on the dressing of hybrid bond CBN wheels using a conventional SiC dressing wheel and a short-pulse fiber laser,« Proceedings of the 11th International Conference on Management of Innovative Technologies and 2nd International Conference on Sustainable Life in Manufacturing, 2011, Fiesa, Slowenien, ISBN 978-961-6536-57-8, Seiten 170-177

Rabiey, M; Dold, C.; Transchel, R.; Wegener, K.;: „ Influence of picosecond laser touch dressing of electroplated diamond wheels on the dressing of SiC vitrified bond wheel, ISAAT Conference, 24-27, Sep. 2011, Stuttgart, Germany

Papers in technical magazines (without scientific reviewing)

2007

Tawakoli, T; Rabiey, M.: „Trockenschleifen mit CBN-Werkzeuge – ein innovative Strukturierung“, Metalbearbeitung Ausgabe August 2007, pp. 46-47

Lectures

2023

Rabiey, M.: CFK Bearbeitung mit superabrasiven Schleifwerkzeugen, Swiss Plastics Expo, Luzern, 19. January 2023
Link to the video of the lecture (German)

2017

Rabiey, M.: TFZ: Verein Technologie Forum Zug: Additive Fertigung – aktuelle Entwicklung und Perspektiven für Produktentwicklung, Materialien, Technologien, Qualität, 30.11.2017, Zug

Rabiey, M.: Hybridprozess mit additiver Fertigung, 12. Rapperswiler Kunststoff-Forum, HSR Hochschule für Technik Rapperswil, 07.09.2017

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