Details
| Original language | English |
|---|---|
| Pages (from-to) | 379-382 |
| Number of pages | 4 |
| Journal | Procedia CIRP |
| Volume | 82 |
| Early online date | 5 Jul 2019 |
| Publication status | Published - 2019 |
| Event | 17th CIRP Conference on Modelling of Machining Operations, CIRP CMMO - Sheffield, United Kingdom (UK) Duration: 13 Jun 2019 → 14 Jun 2019 |
Abstract
Multi-dexel based material removal simulations provide a fast and flexible way to compute process forces and tool deflections for milling and turning operations. This allows an advanced process planning including detection of collisions for complex toolpaths. However, using dexel simulations for designing cutting tools has rarely been investigated. Especially the position of individual cutting edges is not considered, because current approaches only subtract the sweep volume of the tool envelop instead of the rake face. This paper presents a new method to design cutting tools using material removal simulations and a detailed tool geometry representation. The discretization of the tool allows an efficient calculation of the engagement conditions of individual cutting edges. The method is used to optimize novel porcupine milling cutters with round indexeble inserts, which produces a geometry analogous to serrated end mills. Based on the calculated forces, the positions of individual indexable inserts are adjusted to minimize the maximum radial force. An optimum has been found that reduces radial force by 12% compared to conventional porcupine milling cutters with squared inserts.
Keywords
- Geometric modeling, Optimization, Simulaton
ASJC Scopus subject areas
- Engineering(all)
- Control and Systems Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Procedia CIRP, Vol. 82, 2019, p. 379-382.
Research output: Contribution to journal › Conference article › Research › peer review
}
TY - JOUR
T1 - Optimization of complex cutting tools using a multi-dexel based material removal simulation
AU - Denkena, B.
AU - Grove, T.
AU - Pape, O.
N1 - Funding information: The IGF-project (IGF – 19654 N WSF) of the Research Association (FGW) was supported by the AiF within the program for the promotion of industrial research (IGF) from the Federal Ministry of Economy and Energy due to a decision of the German Bundestag. The authors would like to thank the Walter AG for providing the cutting tools.
PY - 2019
Y1 - 2019
N2 - Multi-dexel based material removal simulations provide a fast and flexible way to compute process forces and tool deflections for milling and turning operations. This allows an advanced process planning including detection of collisions for complex toolpaths. However, using dexel simulations for designing cutting tools has rarely been investigated. Especially the position of individual cutting edges is not considered, because current approaches only subtract the sweep volume of the tool envelop instead of the rake face. This paper presents a new method to design cutting tools using material removal simulations and a detailed tool geometry representation. The discretization of the tool allows an efficient calculation of the engagement conditions of individual cutting edges. The method is used to optimize novel porcupine milling cutters with round indexeble inserts, which produces a geometry analogous to serrated end mills. Based on the calculated forces, the positions of individual indexable inserts are adjusted to minimize the maximum radial force. An optimum has been found that reduces radial force by 12% compared to conventional porcupine milling cutters with squared inserts.
AB - Multi-dexel based material removal simulations provide a fast and flexible way to compute process forces and tool deflections for milling and turning operations. This allows an advanced process planning including detection of collisions for complex toolpaths. However, using dexel simulations for designing cutting tools has rarely been investigated. Especially the position of individual cutting edges is not considered, because current approaches only subtract the sweep volume of the tool envelop instead of the rake face. This paper presents a new method to design cutting tools using material removal simulations and a detailed tool geometry representation. The discretization of the tool allows an efficient calculation of the engagement conditions of individual cutting edges. The method is used to optimize novel porcupine milling cutters with round indexeble inserts, which produces a geometry analogous to serrated end mills. Based on the calculated forces, the positions of individual indexable inserts are adjusted to minimize the maximum radial force. An optimum has been found that reduces radial force by 12% compared to conventional porcupine milling cutters with squared inserts.
KW - Geometric modeling
KW - Optimization
KW - Simulaton
UR - http://www.scopus.com/inward/record.url?scp=85070438788&partnerID=8YFLogxK
U2 - 10.1016/j.procir.2019.04.052
DO - 10.1016/j.procir.2019.04.052
M3 - Conference article
AN - SCOPUS:85070438788
VL - 82
SP - 379
EP - 382
JO - Procedia CIRP
JF - Procedia CIRP
SN - 2212-8271
T2 - 17th CIRP Conference on Modelling of Machining Operations, CIRP CMMO
Y2 - 13 June 2019 through 14 June 2019
ER -