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

F Klocke,M Witty,L Rohde,G F Cabral,T Bergs,M Busch

doi:10.1155/2011/742360

F Klocke, M Witty + Show 4 more

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https://doi.org/10.1155/2011/742360

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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.

Highlights

IntroductionNickel-based alloys possess a low thermal conductivity, high rigidity, low elastic modulus, and high chemical reactivity at elevated temperatures
A common task is the manufacture of complex geometrical features, that can be abstracted to notches or slots described by two or three boundaries, as they occur, for example, in the geometries of Blisks, single blades, and landing gears; see Figure 1
The demand for an integrated approach for a knowledge-based process layout originates which links a comprehensive understanding of the chip formation process to the resulting loads at the tool

Summary

Introduction

Nickel-based alloys possess a low thermal conductivity, high rigidity, low elastic modulus, and high chemical reactivity at elevated temperatures They are characterized by a lamellar chip formation process leading to dynamic fatigue stress at the tool and to an increased tool wear [4,5,6,7,8]. The high aspect ratios of the complex geometries require the usage of tools with long shafts and small diameters, which restrains the process velocities even more. For milling such components, several different strategies have been used in the past [9, 10]. The demand for an integrated approach for a knowledge-based process layout originates which links a comprehensive understanding of the chip formation process to the resulting loads at the tool

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