Process design for 5-axis ball end milling using a real-time capable dynamic material removal simulation
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PRODUCTION PROCESS
Process design for 5‑axis ball end milling using a real‑time capable dynamic material removal simulation B. Denkena1 · O. Pape1 · A. Krödel1 · V. Böß1 · L. Ellersiek1 · A. Mücke1 Received: 20 August 2020 / Accepted: 13 November 2020 © The Author(s) 2020
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. Keywords Process stability · Milling · Simulation · Dexel
1 Introduction Because of rising demands for economic and sustainable product life cycles, the relevance of efficient repair processes increases [1]. An example for products for which a repair is highly motivated are Blade integrated disks (Blisks) made from Ti-6Al-4V. 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. Depending on the type of damage, an additional material deposit by welding or brazing might be required to build up the damaged region. Afterwards, the excessive deposit material has to be removed to restore the original geometry. This material removal is carried out using grinding or milling processes. The so-called re-contouring process differs from new part production, because of the uniqueness of each repair case and often-different material properties due to the welding * L. Ellersiek [email protected]‑hannover.de 1
Institute of Production Engineering and Machine Tools, Leibniz Universität Hannover, Hanover, Germany
or brazing filler [2]. The uniqueness of each repair case also prevents running-in processes, which are commonly used in new part production. Thus, the milling process has to be designed individually for each repair case beforehand. Therefore, a virtual process simulation is considered beneficial [2]. For re-contouring, 5-axis ball end milling is typically used, due
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