1. Process design for 5-axis ball end milling using a real-time capable dynamic material removal simulation
- Author
-
O. Pape, Alexander Krödel, Lars Ellersiek, Volker Böß, A. Mücke, and Berend Denkena
- Subjects
0209 industrial biotechnology ,Topography ,Flexible materials ,Design ,Turbine blade ,Computer science ,Dewey Decimal Classification::600 | Technik::620 | Ingenieurwissenschaften und Maschinenbau ,Mechanical engineering ,Process design ,02 engineering and technology ,Shape deviations ,medicine.disease_cause ,Industrial and Manufacturing Engineering ,Dexel ,Nickel alloys ,law.invention ,Ball milling ,020901 industrial engineering & automation ,0203 mechanical engineering ,law ,Mold ,medicine ,Titanium alloys ,Unstable process ,Running-in process ,Ball mill ,Milling ,Mechanical Engineering ,Titanium alloy ,Turbomachine blades ,Hard to cut material ,Process stability ,3D printers ,Vibration ,020303 mechanical engineering & transports ,Dynamic materials ,Additive manufacturing process ,Ball (bearing) ,ddc:620 ,Milling (machining) ,Simulation - 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.
- Published
- 2021