Abstract
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.
Highlights
Because of rising demands for economic and sustainable product life cycles, the relevance of efficient repair processes increases [1]
This paper presents a dynamic material removal simulation, which is able to run in real-time, eliminating the disadvantage of long computation times of existing approaches
The simulation presented in this paper allows a precise virtual process planning for arbitrary complex processes targeting process stability as well as geometric accuracy
Summary
Because of rising demands for economic and sustainable product life cycles, the relevance of efficient repair processes increases [1]. They are commonly used within compressor stages of jet engines, because of a better power-to-weight ratio Due to their integral construction and complex geometries, flexible and efficient repair processes are needed if one blade is damaged during operation. Kersting et al extends the model by considering workpiece vibrations [8] In both approaches, the cutting edges of the tool are not modelled discretely, preventing the prognosis of surface topography errors due to e.g. cutting edge chipping or helix angle effects. The simulation is able to predict high-resolution surface topography including effects of discrete-modelled cutting edges. This allows an optimization of the re-contouring process with respect to geometric accuracy
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