Integrated Approach for a Knowledge-Based Process Layout for Simultaneous 5-Axis Milling of Advanced Materials

Abstract

Advanced materials, like nickel-based alloys, gain importance in turbomachinery manufacturing, where creating complex surfaces constitute a major challenge. However, milling strategies that provide high material removal rates at acceptable tooling costs demand optimized tool geometry and process parameter selection. In this paper, a description of circular milling is given, focusing on resulting engagement conditions. Regarding this, a test bench was designed to investigate the chip formation process in an analogy milling process. Furthermore, the methodology for the approach in the analogy process was developed. Results of a first test run in Inconel 718 verify the presented approach.

Trochoidal Milling Path with Variable Feed. Application to the Machining of a Ti-6Al-4V Part

“…The slope and transformation of an elliptical trochoidal path was previously studied [30]. In this research, the elliptical trochoid was graphically analysed, as seen in Figures 9 and 21 The 20 • elliptical path keeps the value of a eff more stable, being necessary to optimize its parameters [30,31]. However, the circular trochoidal path was tested, with the objective of studying the feed per tooth variation to maintain the chip thickness constant.…”

“…After analysing references [30] and [31], it would be interesting to test these new paths by varying the F in further research.…”

Analytical model of temperature distribution in metal cutting based on Potential Theory

“…As only the shape of the isotherms is of importance no scale is provided. The experiments were conducted on an analogy test rig for orthogonal metal cutting, the test rig is described in Klocke et al (2011). The infrared images were taken by an online calibration measurement method combining two-colour parameter with a high-speed infrared camera, details can be found in Gierlings and Brockmann (2013).…”