Stochastic Modeling of the Interaction of Tool Wear and the Machining Affected Zone in Nickel-Based Superalloys and Application in Dynamic Stability

镍基高温合金刀具磨损与加工影响区相互作用的随机模型及其在动态稳定性中的应用

基本信息

批准号：
400845424
负责人：
Professorin Dr.-Ing. Petra Wiederkehr
金额：
--
依托单位：
Informatik XIV- Lehrstuhl Software-Engineering
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2018
资助国家：
德国
起止时间：
2017-12-31 至 2021-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/400845424?language=en
关键词：
Stochastic Modeling Interaction Tool Wear

项目摘要

In many industrial sectors, e.g., the energy or aerospace industry, Nickel-based alloys are commonly used for various applications due to their high temperature resistance. Unfortunately, this advantage leads to a poor machinability of the material, resulting in high process forces and significant tool wear in milling processes. Due to the complex dependencies between process parameters, process forces, tool wear, and especially the material affected zone when machining Nickel-based alloys, a simulation-based analysis of the processes is required in order to optimize the machining process and to increase the quality of the manufactured parts. Based on a detailed analysis of these dependencies, new models for predicting process forces, tool wear, process dynamics, and the resulting surface topographies will be developed in this project.A special focus of these investigations is set on the analysis and description of the stochastic nature of the tool wear. To analyze the wear and its influence on the process forces systematically, inserts will be worn artificially in order to ensure reproducible process states with defined tool wear, which corresponds to the wear patterns occurring in experiments. These inserts with contrived tool wear will be used in orthogonal cutting tests on a fundamental chip formation machine with controllable process conditions in order to analysis the resulting process forces and to develop appropriate models, before conducting milling experiments on a 5-axis machining center.In addition to the process forces, the tool wear has a significant influence on the process dynamics and the machined surface topographies. In order to predict these surface topographies with respect to tool wear, a model of the worn cutting edges based on triangle meshes will be developed and used to calculate a simplified sweep volume for an efficient simulation of the cutting process. In order to take wear-dependent effects into account when optimizing machining processes, e.g., by a specific design of trochoidal milling paths, the developed models will be integrated into a geometric physics-based simulation system, which can be used to analyze complex machining processes. Taking the stochastic nature of the process into account, probability distributions of the process forces and resulting tool wear can be modeled. Based on the developed models, the extended simulation system will be used to calculate fuzzy stability charts in order optimize milling processes.This project is a collaboration between the Clemson University in South Carolina, USA (funded by the NSF) and the TU Dortmund University.

在许多工业领域，例如能源或航空航天行业中，镍基合金通常用于各种应用，因为它们的高温耐药性。不幸的是，这种优势导致材料的可加工性差，导致高过程力和铣削过程中的显着工具磨损。由于过程参数，过程力，工具磨损，尤其是加工镍基合金之间的材料影响区之间的复杂依赖性，因此需要对过程进行基于模拟的分析，以优化加工过程并提高制成部分的质量。基于对这些依赖关系的详细分析，将在该项目中开发出用于预测过程力，工具磨损，过程动力学以及结果表面地形的新模型。这些研究的特别重点是对工具磨损的随机性质的分析和描述。为了系统地分析磨损及其对过程力的影响，将插入插入物，以确保具有定义的工具磨损的可重复过程状态，这与实验中发生的磨损模式相对应。这些带有人为工具磨损的插入物将用于具有可控过程条件的基本芯片形成机上的正交切割测试，以分析所得的过程力并开发适当的模型，然后再对5轴加工中心进行铣削实验。在过程力量外，该工具对工艺的磨损对工艺动力学和机理表面上的影响有重大影响。为了预测这些表面地形相对于工具磨损，将开发基于三角形网格的磨损切割边缘模型，并用于计算简化的扫描量，以有效地模拟切割过程。为了在优化加工过程（例如，通过特定的木磨铣路路径设计）时考虑磨损依赖性效果，开发的模型将集成到基于几何物理学的仿真系统中，该模型可用于分析复杂的加工过程。考虑到过程的随机性质，可以对过程力的概率分布和生成的工具磨损进行建模。基于开发的模型，扩展模拟系统将用于计算模糊稳定性图表，以优化铣削过程。该项目是美国南卡罗来纳州克莱姆森大学（由NSF资助）与Tu Dortmund大学的合作。