SUNConferences, COMA '13

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Innovative Approach for a Fast and Knowledge-Based Milling Process Design of Advanced Materials
Thomas Bergs, Marc Busch, Michael Ottersbach

Last modified: 2013-08-20


The call for green technologies, new improved and lighter materials in combination with more economic manufacturing processes are current challenges in nearly all industrial fields.

Notably, this applies in the turbo machinery manufacturing for the energy and aviation industry, where legal and ecological regulations and restrictions result in the need for radical new product concepts. However, the development of such products is significantly triggered by the application of innovative materials, which is the reason why turbo machinery manufacturers are permanently looking for advanced materials, like nickel or titanium based alloys. Certainly the properties of these alloys result in complex thermo-mechanical loads on the tools during the machining processes, which lead to increased tool wear. Finally high tool demand, long machining times and bad surface qualities of the manufactured parts are the consequence. To overcome these drawbacks the design of milling strategies, that are able to realize good surfaces in combination with high material removal rates at acceptable tooling costs are an inevitable must. However, the layout of high performing machining processes assumes comprehensive understanding of the procedures and interdependencies, which occur during the machining process between the tool and the work piece. On this basis the realization of advanced machining operations becomes feasible within very short time, to fulfill short time-to-markets, which are required in the addressed sectors.

In this paper an innovative approach will be presented showing how fundamental process knowledge can be determined and used for the design of high-performing, multi-axis milling processes for machining advanced materials. Therefore, investigations regarding the fields of process modelling, simulation, material analysis and analogy milling tests are performed. The presented approach will be verified with data of machining Inconel 718 and Inconel DA 718.

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