Details
| Original language | English |
|---|---|
| Pages (from-to) | 89-95 |
| Number of pages | 7 |
| Journal | Production Engineering |
| Volume | 15 |
| Issue number | 1 |
| Early online date | 28 Nov 2020 |
| Publication status | Published - Feb 2021 |
Abstract
For repairing turbine blades or die and mold forms, additive manufacturing processes are commonly used to build-up new material to damaged sections. Afterwards, a subsequent re-contouring process such as 5-axis ball end milling is required to remove the excess material restoring the often complex original geometries. The process design of the re-contouring operation has to be done virtually, because the individuality of the repair cases prevents actual running-in processes. Hard-to-cut materials e.g. titanium or nickel alloys, parts prone to vibration and long tool holders complicate the repair even further. Thus, a fast and flexible material removal simulation is needed. The simulation has to predict suitable processes focusing shape deviations under consideration of process stability for arbitrary complex engagement conditions. In this paper, a dynamic multi-dexel based material removal simulation is presented, which is able to predict high-resolution surface topography and stable parameters for arbitrary processes such as 5-axis ball end milling. In contrast to other works, the simulation is able to simulate an unstable process using discrete cutting edges in real-time.
Keywords
- Dexel, Milling, Process stability, Simulation
ASJC Scopus subject areas
- Engineering(all)
- Mechanical Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Production Engineering, Vol. 15, No. 1, 02.2021, p. 89-95.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Process design for 5-axis ball end milling using a real-time capable dynamic material removal simulation
AU - Denkena, B.
AU - Pape, O.
AU - Krödel, A.
AU - Böß, V.
AU - Ellersiek, L.
AU - Mücke, A.
N1 - Funding Information: The authors kindly thank the German Research Foundation (DFG) for the financial support of the Collaborative Research Center (SFB) 871/3 - 119193472 “Regeneration of Complex Capital Goods” which provides the opportunity of their collaboration in the research projects B2 “Dexterous Regeneration Cell” and C1 “Simulation Based Planning of Re-contouring Metal Cutting Processes”.
PY - 2021/2
Y1 - 2021/2
N2 - For repairing turbine blades or die and mold forms, additive manufacturing processes are commonly used to build-up new material to damaged sections. Afterwards, a subsequent re-contouring process such as 5-axis ball end milling is required to remove the excess material restoring the often complex original geometries. The process design of the re-contouring operation has to be done virtually, because the individuality of the repair cases prevents actual running-in processes. Hard-to-cut materials e.g. titanium or nickel alloys, parts prone to vibration and long tool holders complicate the repair even further. Thus, a fast and flexible material removal simulation is needed. The simulation has to predict suitable processes focusing shape deviations under consideration of process stability for arbitrary complex engagement conditions. In this paper, a dynamic multi-dexel based material removal simulation is presented, which is able to predict high-resolution surface topography and stable parameters for arbitrary processes such as 5-axis ball end milling. In contrast to other works, the simulation is able to simulate an unstable process using discrete cutting edges in real-time.
AB - For repairing turbine blades or die and mold forms, additive manufacturing processes are commonly used to build-up new material to damaged sections. Afterwards, a subsequent re-contouring process such as 5-axis ball end milling is required to remove the excess material restoring the often complex original geometries. The process design of the re-contouring operation has to be done virtually, because the individuality of the repair cases prevents actual running-in processes. Hard-to-cut materials e.g. titanium or nickel alloys, parts prone to vibration and long tool holders complicate the repair even further. Thus, a fast and flexible material removal simulation is needed. The simulation has to predict suitable processes focusing shape deviations under consideration of process stability for arbitrary complex engagement conditions. In this paper, a dynamic multi-dexel based material removal simulation is presented, which is able to predict high-resolution surface topography and stable parameters for arbitrary processes such as 5-axis ball end milling. In contrast to other works, the simulation is able to simulate an unstable process using discrete cutting edges in real-time.
KW - Dexel
KW - Milling
KW - Process stability
KW - Simulation
UR - http://www.scopus.com/inward/record.url?scp=85096919670&partnerID=8YFLogxK
U2 - 10.1007/s11740-020-01003-5
DO - 10.1007/s11740-020-01003-5
M3 - Article
AN - SCOPUS:85096919670
VL - 15
SP - 89
EP - 95
JO - Production Engineering
JF - Production Engineering
SN - 0944-6524
IS - 1
ER -