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Cutting edge preparation of monolithic ceramic milling tools 21

Cutting edge preparation of monolithic ceramic milling tools

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, M. Polte, J. Hocke, T. Fraunhofer Institute for Production Systems Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Due to international competition, continuous increases in productivity, product quality and reduction of production costs are required. Especially, the development of milling tools made of innovative cutting materials and application-specific tool geometries for the machining of brittle materials are in focus to overcome these challenges. One approach to improve the performance and the tool behaviour concerning milling of graphite is the use of monolithic ceramic milling tools. Unfortunately, the high brittleness of the ceramic leads to breakouts on the cutting edge during the grinding process. This results in an increased maximum chipping of the cutting edge, which has a significant influence on the milling process. To improve the breakout behaviour, a cutting edge preparation with the immersed tumbling process was applied. To enable a process reliable cutting edge preparation, a suitable lapping medium, the influence of the processing time as well as the depth of immersion were investigated. Besides the maximum chipping of the cutting edge, the rounded cutting edge radius was also analysed. The results show that a process reliable cutting edge preparation of monolithic ceramic milling tools with a maximum chipping of the cutting edge RS,max ≤ 3 µm and a rounded cutting edge radius of rβ ≤ 7 µm could be realised. In future investigations, the experimental applicability of monolithic ceramic milling tools will be proved. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Brittleness

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Precision finishing of additively manufactured components using the immersed tumbling process 21

Precision finishing of additively manufactured components us...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Polte, J. Polte, M. Hocke, T. Lahoda, C. Uhlmann, E. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Additive manufacturing enables the production of highly complex metallic components with highest geometrical flexibility in dedicated lightweight construction. For titanium-aluminium alloys, which are used in particular in the aviation industry, powder bed based processes such as the laser powder bed fusion are established. Nevertheless, laser powder bed fusion is limited with regard to the producible surface roughness in a range of 5 µm ≤ Ra ≤ 15 µm. According to the state of the art, the increase of the geometrical accuracy and the reduction of the surface roughness values of the additive manufactured components are realised by different cutting and non-conventional processes. In this investigation, a new approach for the reduction of the surface roughness values by immersed tumbling was realised. Therefore, additively manufactured square bars made of the titanium alloy Ti-5Al-5Mo-5V-3Cr were used as sample geometries. An immersed tumbling machine tool with planetary kinematics for post-processing was applied and the lapping media QZ, HSC 1/500 and M5/400 were evaluated. In addition, the influence of the rotor speed and the holder as well as the depth of immersion were considered as influencing factors. As target values the surface roughness values as well as the rounded edge radius were examined. Within this investigations the surface roughness values could be reduced by more than 90 %. In addition, a targeted rounding of the edges could be obtained, which removed the excess edge height at the part resulting from the laser powder bed fusion process. As a result the immersed tumbling process shows a great suitability as a finishing process for additively manufactured components and is particularly suitable for automated and serial finishing processes. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Surface roughness

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Particle contact conditions for cutting edge preparation of micro-milling tools by the immersed tumbling process 21

Particle contact conditions for cutting edge preparation of ...

引用

21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, J. Kuche, Y. Landua, F. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

For increasing tool life and cutting length of micro-milling tools the cutting edge preparation was successfully established. Using the immersed tumbling process, a reproducible cutting edge preparation with constant cutting edge radii as well as low chipping of the cutting edges can be realised. For a profound understanding of the preparation process and the process mechanisms further knowledge about the particle interactions with cutting tools as well as the particle flow mechanisms needs to be obtained. In this investigation the preparation process of micro-milling tools was analysed and the contact-mechanisms as well as the resulting pressures were investigated by simulation studies. Using the discrete element method (DEM) with the software ROCKY DEM from the company ESSS, Florianópolis, Brasil, the immersed tumbling process could be modelled and particle contacts, particle traces as well as particle interactions with the micro-milling tool can be visualized. Especially the particle-tool interactions were more accurately investigated by analysing the stresses and particles shear work as well as correlations between these parameters to prove the comparability between the process simulation and the real preparation process. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Milling (machining)

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REPLICATION OF FUNCTIONAL SURFACES MICRO-STRUCTURED BY EDM 37

REPLICATION OF FUNCTIONAL SURFACES MICRO-STRUCTURED BY EDM

引用

37th Annual Meeting of the American Society for Precision Engineering, ASPE 2022

作者： Uhlmann, Eckart Polte, Mitchel Ludwig, Jonas Bolz, Robert Technische Universität Berlin Institute for Machine Tools and Factory Management Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

ISBN: (纸本)9781887706568

Functional surfaces are applied in a broad range of industries ranging from automotive over aerospace to medical technology. In this paper, the manufacturing of molds micro-structured by sinking electrical discharge machining (sEDM) and the surface replication on polycarbonat (PC) is discussed. The presented analysis shows the ability to replicate hydrophobic and hydrophilic effects on PC samples from micro-structured molds fabricated by sEDM. © 2022 Proceedings - ASPE 2022 Annual Meeting. All right reserved.

关键词： Molds

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Tool wear and surface roughness in micro-milling of aluminium and high-alloyed aluminium materials using cutting tools made of binderless carbide 21

Tool wear and surface roughness in micro-milling of aluminiu...

引用

21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Polte, M. Hein, C. Polte, J. Wiesner, H.M. Fraunhofer Institute for Production Systems Design Technology IPK Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Micro-milling can be applied for manufacturing in a wide range of materials and complex geometries. This process is especially important for the aerospace industry. High-alloyed aluminium is a common material for aerospace applications with complex micro- and macro-geometry due to its high wear resistance. The costs-effectiveness of producing these parts can be increased by using tools with improved wear behaviour and higher life times. However, wear-resistant tools are often associated with higher tool costs, which reduces the cost-effectivness of the whole production. An innovative solution is offered by the use of a cutting tool made of binderless tungsten carbide. The micro-milling of conventional and high-alloy aluminium with a new cutting material based on a binderless tungsten carbide is analysed in this investigation. The absence of a binding phase leads to an increased hardness and improves the wear behaviour of these tools. Therefore, tools with a tool diameter of D = 10 mm were manufactured and there machinability was successfully proven. The feasibility of these innovative tools is demonstrated in a series of experiments. The experimental investigations were carried out on the five-axis high precision machine tool PFM 4024-5D PRIMACON GMBH, Peißenberg, Germany, with a workpiece made of TiAl 48-2-2. A surface roughness of Ra = 0.202 µm was detected after a path length due to primary motion lc = 70 m without any noticeable wear marks on the cutting tool. These results show the economic potential for milling tools based on binderless carbide for achieving high precision surfaces while reaching high lifetimes. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Milling (machining)

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Investigation of additive manufactured tungsten carbide-cobalt tool electrodes for sinking EDM 37

Investigation of additive manufactured tungsten carbide-coba...

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37th Annual Meeting of the American Society for Precision Engineering, ASPE 2022

作者： Uhlmann, Eckart Polte, Mitchel Hörl, Robert Braun, Thomas Bolz, Robert Technische Universität Berlin Institute for Machine Tools and Factory Management Berlin Germany Fraunhofer Institute for Production Systems and Design Technology Berlin Germany

ISBN: (纸本)9781887706568

Increasing product complexity and continuous developments in related tool and mould making industry require ongoing advances in manufacturing processes like electrical discharge machining (EDM). To meet the increasing requirements, the development of adapted EDM processes and tool designs is necessary. Additive manufacturing (AM) enables the manufacturing of complex tool electrode geometries with interior flushing channels for EDM processes with very few restrictions regarding the design. This accounts even for tungsten carbide-cobalt (WC-Co), which is a suitable material for EDM tool electrodes with various advantages, e.g. thermal and mechanical stability. This paper shows first results of additive manufactured WC-Co tool electrodes for the use in sinking EDM and the related development process. © 2022 Proceedings - ASPE 2022 Annual Meeting. All right reserved.

关键词： Additives

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Simulating flow behaviour of wet particles within the immersed tumbling process 21

Simulating flow behaviour of wet particles within the immers...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

ISBN: (纸本)9780995775190

For many production chains, it is mandatory to involve special finishing of the manufactured parts for the chipping of the edges as well as the polishing of surfaces. One commonly used method is the immersed tumbling process, where any workpiece is dragged through a particle filled container. In many cases, the immersed tumbling process operates in environments with added liquids, leading to changes in particle-tool interaction and general flow behaviour of the used particles. Whilst the discrete element method for simulating particles is mainly limited to dry particles, the used software ROCKY DEM from ESSS, Florianópolis, Brasil, comes with a built-in liquid-bridge model to simulate water-covered particles and granulate and furthermore an extension for system couplings with Ansys Fluent of the company ANSYS, INC., Canonsburg, Pennsylvania. The latter can be used to create from both software one three-phase-model with higher amounts of actually simulated water. In this study, small amounts of water were added to differently shaped particles using the build-in liquid-bridge model, to analyse and compare the particles flow characteristics in both, wet and dry environments. To gather significant information leading towards precise comparisons, the particles trajectories, velocities and resulting forces against the workpieces can be specifically observed and analysed, whilst this kind of process knowledge could previously never been taken into account without simulation. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Liquids

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Single pass laser vacuum welding of thick steel plates using electromagnetic support.-Invited Paper- 13

Single pass laser vacuum welding of thick steel plates using...

引用

13th CIRP Conference on Photonic Technologies, LANE 2024

作者： Gumenyuk, Andrey Üstöndag, Ömer Pelz, Till Bakir, Nasim Gerhards, Benjamin Schleser, Markus Rethmeier, Michael Unten den Eichen 87 Berlin12205 Germany LaVa-X GmbH Kaiserstrasse 100 Herzogenrath52134 Germany FH Aachen-University of Applied Science Bayernallee 11 Aachen52066 Germany Technische Universität Berlin Pascalstrasse 8-9 Berlin10587 Germany Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 Berlin10587 Germany

The increasing demand for renewable energy produced by offshore wind turbines goes along with an increased demand in the production of offshore wind turbine foundations, so called "monopiles", which are made by joining thick metal sheets. The industrial standard of multi-layer submerged arc welding (SAW) for joining of thick metal sheets is the current bottleneck in the production of monopiles. A possible increase in productivity by the implementation of high-power laser welding in a newly developed mobile vacuum chamber (MoVac) and an electromagnetic root support is the subject of this study. Single run butt welds are performed in flat position on S355 mild steel of thicknesses up to 80 mm using a disc laser system with 1030 nm wavelength and a maximum output of 60 kW. The laser optic is fixed on the MoVac-System which is held and manipulated by an articulated robot. © 2024 The Authors.

关键词： Vacuum welding

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Process strategies for optimizing the cooling behaviour of laser-welded Tailor Welded Blanks made of advanced high strength steels (AHSS) 13

Process strategies for optimizing the cooling behaviour of l...

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13th CIRP Conference on Photonic Technologies, LANE 2024

作者： Lemke, Josefine Höfemann, Matthias Biegler, Max Rethmeier, Michael Fraunhofer Institute for Production Systems and Design Technology IPK Pascalstrasse 8-9 Berlin10587 Germany Unter den Eichen 87 Berlin12205 Germany Institut for Werkzeugmaschinen und Fabrikbetrieb IWF Technische Universität Berlin Strasse des 17. Juni 135 Berlin10623 Germany Salzgitter Mannesmann Forschung GmbH Eisenhöttenstraße 99 Salzgitter38239 Germany

AHSS with 1000 MPa tensile strength show promising properties for the use in Tailor Welded Blanks (TWBs) to locally strengthen car body parts. Challenges in laser beam welding of the sheets are hardness-drops and-peaks in the heat-Affected zone (HAZ) and weld, which cause risks during cold-forming. This happens due to rapid cooling caused by laser welding. A numerical approach aiming for slower cooling rates in the weld region is presented in this article. Laser welded sheets served as reference for setting up a process simulation. Models for pre-heating and a coaxial setup with power split were set up. A correlation between cooling-rate and hardness in the joining zone was established and applied to the modelled strategy. Splitting the power led to a slightly narrower weld seam and experimental pre-heating of the sheets to 600 °C could lower total seam hardening. It achieved a homogenization of the fusion zone. © 2024 The Authors.

关键词： Laser beam welding

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Development of a mechanical, biocide-free method of disinfection for cathodic dip coating processes 21

Development of a mechanical, biocide-free method of disinfec...

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21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021

作者： Uhlmann, E. Hilt, M. Hein, C. Cudazzo, M. Huth-Herms, K. Jahnke, C. Quast, M. Fraunhofer Institute for Production Systems and Design Technology IPK Germany Fraunhofer Institute for Manufacturing Engineering and Automation IPA Germany Institute for Machine Tools Factory Management IWF Technische Universität Berlin Germany

ISBN: (纸本)9780995775190

Technical fluids are often contaminated by bacteria as Burkholderia cepacia (B. cepacia), which is found in different industrial issues and affects manufacturing process chains by the formation of planktonic cell-aggregates and biofilms within the working fluids. B. cepacia is one of nine species of the Burkholderia cepacia complex (Bcc), a group of gram-negative, motile, non-spore-forming, and rod-shaped bacteria. Because of the opportunistic pathogenicity to plants, animals, humans, and the multi-drug and biocide resistance, B. cepacia is difficult to treat. This study aims to provide an application to reduce the germ numbers ng in an eco-friendly and continuous process without the use of biocides. The approach to disinfect technical fluids is to apply high shear forces in a rotor-stator assembly to the fluid. A prototype of the rotor-stator assembly with a variably adjustable shear gap gs and rotor speed srot was constructed. First experiments with a frequency frot 10 Hz ≤ frot ≤ 40 Hz a shear gap gs = 83 µm and gs = 166 µm showed a reduction of germ number ngr = 99.6 %. It concluded that the disinfection of technical fluids by a rotor-stator assembly is a biocide-free alternative. In addition to defined process parameters such as shear gap gS, temperature ϑ, frequency frot and time of machining process tmp, also the peripheral speed vp, rotational speed vrot, flow rate fr and shear stresses τ were used to assess the machining result and to develop an overall concept for disinfection of technical fluids. © 2021 Proceedings of the 21st International Conference of the European Society for Precision Engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Stators

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