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HANNOVER MESSE 2018, 23 - 27 April
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Analysis of milling

Kinematic simulation of five-axle milling of composites.

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Exhibitor

Karlsruher Institut für Technologie

Exhibitor details
Exhibitor details
Logo Analysis of milling

Product description

During mechanical machining of fiber-reinforded plastics, process forces acting in unfavorable direction may damage the workpiece, as composites are highly heterogeneous and anisotropic in their properties. Mechanical machining often results in forces that act in outward direction in the cover layer and strongly damage the component. Tools and process strategies that direct the resulting process forces into the interior of the workpiece produce a high quality of machining. An example of such machining strategy for boreholes is five-axle milling. The cover layer of a borehole is machined with an inclined miller rotating around a fixed point. During cutting, cutting and passive forces at the cutting edge of the tool are always directed towards the center of the workpiece, as a result of which the cover layers are supported by the workpiece itself. Consequently, only minimum damage, such as spalling or delamination, occurs.A simulation program developed by the Institute of Production Science allows for the precise analysis of the complex milling process and of the cutting conditions existing when cutting the plastic. The existing and constantly changing cutting cross-section is used as a control parameter, on the basis of which the resulting process forces are determined by an empirically determined model.By means of the new simulation program, the process forces acting at any point at the tool cutter can be determined and the undeformed chip geometry can be calculated. Tool movement can be described in a freely parameterized manner by three translatory and two rotatory degrees of freedom. Process analysis takes place in discrete time steps. It is aimed at reliably representing the process forces acting on the material in amount and direction for any tool movements in order to keep the load always below the strength of the workpiece.

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Hall 2, Stand B16

(Main stand)

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