Prof. Dr.-Ing. habil. Carsten Heinzel,Bremen University, Germany

Title
Process performance, energy efficiency and surface integrity during grinding
Abstract
An effective supply of grinding fluids to the contact zone between tool and workpiece allows for significantly improved machining conditions during conventional grinding of highly loaded mechanical components such as shafts, gears and prismatic steel parts. As a result, the thermomechanical load on the workpiece is reduced and the process performance can be increased without negatively affecting surface and sub-surface of the workpiece. In addition, energy consumption is reduced due to flow-optimised fluid supply nozzles and a fluid flowrate which is reduced to the required minimum. As a result, fluid supply systems can be dimensioned smaller. This significantly increases the energy efficiency and economy of industrial grinding processes. Practical examples show a potential of 20-30% of savings.
It can be deduced from the investigations to be presented that already flow-optimised nozzle concepts enable efficient lubrication, cooling and tool cleaning - even with a strongly reduced fluid flowrate. This allows more productive machining conditions to be set with lower process forces. The resulting reduced thermomechanical load on the tool and the workpiece opens up potential for further increases in process performance and reliability. In addition, a reduction in the fluid flowrate reduces the energy consumption of the fluid pumps and the fluid systems can be dimensioned smaller. A significant increase in the energy efficiency and cost-effectiveness of the overall process can thus be achieved.
The approaches tob e shown point to significant potential for increasing process performance and economy in conventional grinding of mechanical parts and can often be implemented directly in industrial practice with only little additional effort. 
Biography
Prof. Dr.-Ing. habil. Carsten Heinzel received the diploma degree in mechanical engineering from the Technical University in Berlin in 1994 and the Dr.-Ing. degree for his doctoral thesis on Fluid Supply in Grinding from the University of Bremen in 1999. After his studies in Germany (Berlin) and in France (Valenciennes & Lyon) he joined the Leibniz Institute for Materials Engineering (formerly known as Foundation Institute for Materials Science) – IWT – in Bremen, Germany, Dept. Manufacturing Technologies, and became chief engineer in 1998. In 2012 he became honorary professor at the University of Bremen for the area of manufacturing processes and head of the group Materials oriented Manufacturing. Today he is vice-head of the IWT Dept. Manufacturing Technologies and of the Dept. for Manufacturing Processes at the Faculty for Production Engineering of the University of Bremen. Prof. Heinzel’s research is focusing on cutting and abrasive machining and ultra-precision machining as well, on prevention of material damage in machining and surface integrity of machined workpieces, on the optimization of fluid supply conditions in machining, on the integration of sensors in grinding tools and on the complex interaction of machining process and sequences and the material to be machined in general. 
Prof. Heinzel is CIRP Associate Member and Secretary of STC G, he acts as reviewer for several international journals and funding organizations and is principal investigator and member of the board in two collaborative research centers, the SFB TRR 136 on “Process Signatures” and the SFB 1232 on “High-throughput for Evolutionary Structural Materials”, both funded by the German Research Association DFG.