TY - JOUR

T1 - Process design for 5-axis ball end milling using a real-time capable dynamic material removal simulation

AU - Denkena, B.

AU - Pape, O.

AU - Krödel, A.

AU - Böß, V.

AU - Ellersiek, L.

AU - Mücke, A.

N1 - Funding Information: The authors kindly thank the German Research Foundation (DFG) for the financial support of the Collaborative Research Center (SFB) 871/3 - 119193472 “Regeneration of Complex Capital Goods” which provides the opportunity of their collaboration in the research projects B2 “Dexterous Regeneration Cell” and C1 “Simulation Based Planning of Re-contouring Metal Cutting Processes”.

PY - 2021/2

Y1 - 2021/2

N2 - For repairing turbine blades or die and mold forms, additive manufacturing processes are commonly used to build-up new material to damaged sections. Afterwards, a subsequent re-contouring process such as 5-axis ball end milling is required to remove the excess material restoring the often complex original geometries. The process design of the re-contouring operation has to be done virtually, because the individuality of the repair cases prevents actual running-in processes. Hard-to-cut materials e.g. titanium or nickel alloys, parts prone to vibration and long tool holders complicate the repair even further. Thus, a fast and flexible material removal simulation is needed. The simulation has to predict suitable processes focusing shape deviations under consideration of process stability for arbitrary complex engagement conditions. In this paper, a dynamic multi-dexel based material removal simulation is presented, which is able to predict high-resolution surface topography and stable parameters for arbitrary processes such as 5-axis ball end milling. In contrast to other works, the simulation is able to simulate an unstable process using discrete cutting edges in real-time.

AB - For repairing turbine blades or die and mold forms, additive manufacturing processes are commonly used to build-up new material to damaged sections. Afterwards, a subsequent re-contouring process such as 5-axis ball end milling is required to remove the excess material restoring the often complex original geometries. The process design of the re-contouring operation has to be done virtually, because the individuality of the repair cases prevents actual running-in processes. Hard-to-cut materials e.g. titanium or nickel alloys, parts prone to vibration and long tool holders complicate the repair even further. Thus, a fast and flexible material removal simulation is needed. The simulation has to predict suitable processes focusing shape deviations under consideration of process stability for arbitrary complex engagement conditions. In this paper, a dynamic multi-dexel based material removal simulation is presented, which is able to predict high-resolution surface topography and stable parameters for arbitrary processes such as 5-axis ball end milling. In contrast to other works, the simulation is able to simulate an unstable process using discrete cutting edges in real-time.

KW - Dexel

KW - Milling

KW - Process stability

KW - Simulation

UR - http://www.scopus.com/inward/record.url?scp=85096919670&partnerID=8YFLogxK

U2 - 10.1007/s11740-020-01003-5

DO - 10.1007/s11740-020-01003-5

M3 - Article

AN - SCOPUS:85096919670

VL - 15

SP - 89

EP - 95

JO - Production Engineering

JF - Production Engineering

SN - 0944-6524

IS - 1

ER -