High Perfomance Milling (HPM) is one of the most common processes to produce structural parts out of aluminum in the aerospace industry. Using this technology nearly 95% of the raw material are turned into chips. Due to the high feed rates and relatively high cutting speed in high performance processes, the thermal and mechanical loads on the workpiece are much higher than in conventional machining processes. This results in residual stresses which lead to workpiece distortion and though to high waste rates. The interdependences between the process parameters and the residual stresses are not yet fully understood. Because it is nearly impossible to determine the stresses, strains and temperatures that occur during the machining process with a high local resolution, FEM-Simulations are the only possibility to get a higher understanding of the interrelations. Experimental investigations have shown, that the tool corner radius in combination with the feed rate has a high influence on the residual stress. To understand this relationship, 3D-FEM-Simulations have been carried out. These simulations will show the influence of the tool corner radius on the thermomechanical loads on the workpiece. This gives an explanation for the experimental results. The aim of these investigations is a semiempirical model for the prediction of residual stresses out of the process parameters and the tool geometry.
FEM-simulation of high-performance-milling
FEM-Simulation des Hochleistungsfräsens
2007
7 Seiten, 9 Bilder, 1 Tabelle, 18 Quellen
Aufsatz (Konferenz)
Englisch
Fräsen , Hochleistung , Finite-Elemente-Methode , Simulation , Bauteil , Aluminium , Luftfahrtindustrie , Raumfahrtindustrie , Vorschubgeschwindigkeit , Schnittgeschwindigkeit , Restspannung (mechanisch) , Werkstück , Verformung , experimentelle Untersuchung , Schneide , thermomechanische Eigenschaft
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