Analysis of Cutting Technologies for Lightweight Frame Components

Abstract

Most technical components applied in industrial practice are subjected to metal cutting operations during their production process. However, this leads to undesirable thermal and mechanical loads affecting the machined workpiece, which can result in an impairment of its serviceability. Due to their small wall thickness lightweight hollow profiles are highly susceptible to the inevitable machining loads and thermal stresses during drilling processes. For the virtual optimization of the machining process and in order to ensure a suitable process strategy, a finite element simulation of cutting operations for thin-walled light metal profiles is conducted. Due to the flexibility within creating drill holes of different diameters without tool changes circular milling represents a promising alternative to the application of conventional drilling tools for variable process strategies to handle batch sizes down to one piece efficiently. Hence, this article gives an insight into the investigations regarding the modeling concepts of the mechanical and thermal loads induced into the thin-walled lightweight frame structure during the circular milling process. Furthermore, process reliability aspects as well as the correlation of the calculated and the measured results will be discussed on the basis of experimental investigations. Finally, this article compares Finite Element Analysis aspects of circular milling processes with conventional drilling processes.

Integrated simulation of the process chain composite extrusion–milling–welding for lightweight frame structures

“…The omittance of chip and burr formation is an additional simplification due to the main aim of this research, which is the analysis of the peripheral zone of the hole. As shown in former studies [13], the major and minor cutting edges can be represented by lines, a modelling of the whole tool is not necessary to apply the load onto the workpiece. In this present machining process only the major cutting edge is in contact with the work piece (Fig.…”

“…After the calculation for one load step, the node coupling and the force loading is deleted from this current master node and changed to the next master node. Since the MSC.Marc source model has been generated without the designated volume to be removed in the arc area, the stepwise removal of the machined material [13] is not integrated.…”

Experimental and Computational Analysis of Machining Processes for Light-Weight Aluminium Structures

“…Especially these data are important for the definition of loads within the FE-modeling. The simulation model for circular milling previously developed at the Department of Machining Technology (ISF) was applied for the simulation of machining process at section ends [3]. In comparison to the circular milling, the end-cross-section machining is a conventional milling operation without movement in Z-direction.…”

“…The area which will be machined was modeled as a certain volume. As in former analyzes already proved, the approach of discretisizing is a reasonable way to describe the tool movement along the machined workpiece surface [3]. The simulation of the entire process is only performed without investigating the chip building.…”

Redistribution of residual stress in aluminum alloy plate and its effect on bending deformation

“…There has been a lot of research on deformation problems with thin-walled components by domestic and foreign scholars. Weinert [4,5] used finite element method for numerical analysis of the processing process of components and proposed an optimized processing strategy to control processing deformation. Liao Kai [6] measured the initial residual stress of aluminum alloy thin-walled frame members using the layered-cutting method and established a mechanical model of the influence of initial residual stress and processing residual stress on deformation.…”