Abstract
The aerospace industry utilizes nickel-based super-alloys due to its high level of strength and corrosion resistance. To evaluate milling strategies regarding tool wear, the prediction of forces during these cutting operations is essential. This comprises the determination of the undeformed chip thickness. Due to the complex interdependencies of tool engagements, the determination of these thicknesses is challenging. A geometric physically-based simulation system was extended by a novel time-discrete envelope model to increase the precision of the calculated undeformed chip thicknesses. In order to take tool wear into account, digitized topographies of cutting inserts in different states of tool wear were modelled.
Highlights
Nickel-based super-alloys are widely used in the energy and aerospace industry
A new modeling approach is presented, which utilizes different states of tool wear derived from trochoidal milling strategies to increase the precision of the calculated process forces in an existing geometric physically-based simulation system
An extension of a time-domain simulation system was presented which enables the usage of digitized cutting edges for the prediction of process forces
Summary
Nickel-based super-alloys are widely used in the energy and aerospace industry. Difficult-to-cut materials, like Inconel 718, are characterized by a high strength and corrosion resistance, even at high temperatures, which make them especially popular in these sectors [1, 2]. Due to the complex engagement situation of trochoidal paths and the wear-dependent change of the shapes of cutting tools, the prediction of process forces is limited with previous methods, when considering tool wear- to trochoidal milling strategies. In this investigation, a new modeling approach is presented, which utilizes different states of tool wear derived from trochoidal milling strategies to increase the precision of the calculated process forces in an existing geometric physically-based simulation system. The new model is based on the consideration of individual cutting segments in combination with a discrete workpiece representation
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