NSF/DFG Collaboration to Understand the Prime Factors Driving Distortion in Milled Aluminum Workpieces

NSF/DFG 合作了解导致铣削铝工件变形的主要因素

• 批准号: 351381681
• 负责人: Professor Dr.-Ing. Jan C. Aurich
• 金额: --
• 依托单位: Lehrstuhl für Fertigungstechnik und Betriebsorganisation (FBK)
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2017
• 资助国家: 德国
• 起止时间: 2016-12-31 至 2020-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/351381681?language=en
• 关键词: NSF; DFG; Collaboration; Understand; Prime

Thin-walled workpieces of aluminum are distorted during milling due to the residual stresses inside the workpiece. Distortion reduces the machining accuracy. Distortion necessitates time-intensive and expensive rework or can result into rejection. Within this proposal, we will investigate how the distortion of thin-walled monolithic workpieces can be controlled when milling. Experimental investigations are carried out and a finite element model for the prediction of the distortion of the workpiece is developed. Dry milling experiments are conducted to generate fundamental knowledge about the distortion phenomena. These experiments provide a quantitative database for the finite element simulations. The distortion of the workpiece is analyzed with regard to multiple parameters. Those are the cutting condition, the workpiece geometry, the clamping device, as well as the magnitude and distribution of the initial bulk residual stress. The experimental results allow for the specification of required boundary conditions for the finite element model. Moreover, experimental and numerical results can be continuously compared in order to evaluate the capability of the finite element model. The x-ray diffraction method and contour method will be applied to measure the residual stresses. The comparison of the results will facilitate the evaluation of the capability of both methods. This helps to establish or further improve the methods. Workpiece distortion is induced by both bulk and machining residual stresses. Both will be considered in the finite element model. With the numerical and experimental results we will explore the significance of the bulk and machining induced stress for the distortion. Possible stress regimes will be determined, where bulk residual stresses only, machining residual stresses only, or a combination of bulk residual stresses and machining residual stresses define the distortion. Numerically generated milling strategies are experimentally used to investigate the possibility to compensate or counteract bulk residual distortion. The result of the research project is a significant improvement of the machining accuracy, the efficiency, and sustainability in milling of thin-walled monolithic workpieces.

由于工件内部的残余应力，薄壁铝工件在铣削过程中会变形。变形会降低加工精度。失真需要耗时且昂贵的返工，否则可能会导致拒绝。在本提案中，我们将研究铣削时如何控制薄壁整体工件的变形。进行了实验研究并开发了用于预测工件变形的有限元模型。进行干磨实验是为了获得有关变形现象的基础知识。这些实验为有限元模拟提供了定量数据库。针对多个参数来分析工件的变形。这些是切削条件、工件几何形状、夹紧装置以及初始体残余应力的大小和分布。实验结果允许指定有限元模型所需的边界条件。此外，可以不断比较实验结果和数值结果，以评估有限元模型的能力。残余应力的测量将采用X射线衍射法和轮廓法。结果的比较将有助于评估两种方法的能力。这有助于建立或进一步改进方法。工件变形是由体积应力和加工残余应力引起的。两者都将在有限元模型中考虑。通过数值和实验结果，我们将探讨体积应力和加工引起的应力对变形的重要性。将确定可能的应力状态，其中仅体残余应力、仅加工残余应力、或体残余应力和机加工残余应力的组合定义变形。通过实验使用数值生成的铣削策略来研究补偿或抵消整体残余变形的可能性。该研究项目的成果是显着提高了薄壁整体工件铣削的加工精度、效率和可持续性。

项目成果

Concept to analyze residual stresses in milled thin walled monolithic aluminum components and their effect on part distortion

分析铣削薄壁整体铝部件中的残余应力及其对零件变形的影响的概念

• DOI: 10.1007/978-3-662-60417-5_29
• 发表时间: 2019
• 期刊: Production at the leading edge of technology
• 作者: D. Weber; B. Kirsch; C.R. D’Elia; B.S. Linke; M.R. Hill; J.C. Aurich
• 通讯作者: J.C. Aurich

Analysis of machining-induced residual stresses of milled aluminum workpieces, their repeatability, and their resulting distortion

分析铣削铝工件加工引起的残余应力、其重复性以及由此产生的变形

• DOI: 10.1007/s00170-021-07171-7
• 发表时间: 2021-05-22
• 期刊: The International Journal of Advanced Manufacturing Technology
• 作者: D. Weber;B. Kirsch;C. R. Chighizola;C. D'Elia;B. Linke;M. R. Hill;J. Aurich
• 通讯作者: J. Aurich

Intermethod Comparison and Evaluation of Measured Near Surface Residual Stress in Milled Aluminum

铣削铝近表面残余应力测量的方法间比较和评估

• DOI: 10.1007/s11340-021-00734-5
• 发表时间: 2021
• 期刊: Experimental Mechanics
• 影响因子: 2.4
• 作者: C.R. Chighizola; C.R. D’Elia; D. Weber; B. Kirsch; J.C. Aurich; B.S. Linke; M.R. Hill
• 通讯作者: M.R. Hill

Oberflächenmorphologie gefräster Aluminiumwerkstücke

铣削铝工件的表面形貌

• DOI: 10.1515/zwf-2021-0114
• 发表时间: 2021
• 期刊: Zeitschrift für wirtschaftlichen Fabrikbetrieb
• 作者: D. Weber; B. Kirsch; K. Gutzeit; B.S. Linke; M.R. Hill; J.C. Aurich
• 通讯作者: J.C. Aurich

Milling-Induced Residual Stress and Distortion Under Variations of Bulk Residual Stress

体积残余应力变化下铣削引起的残余应力和变形

• DOI: 10.31399/asm.cp.ht2021exabp0096
• 发表时间: 2021
• 期刊: Heat Treat 2021: Extended Abstracts from the 31st Heat Treating Society Conference and Exposition
• 作者: J.E. Jonsson; C.R. Chighizola; C.R. D’Elia; B.S. Linke; M.R. Hill; D. Weber; B. Kirsch; J.C. Aurich
• 通讯作者: J.C. Aurich