Transcript
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Cutting Processes

Simulation Techniques in Manufacturing Technology

Lecture 7

Laboratory for Machine Tools and Production Enginee ring

Chair of Manufacturing Technology

Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke

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Modeling of Machining5

Hard machining4

Cutting processes with parallel translation3

Cutting processes with rotary motion2

Introduction1

Outline

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Breakdown of the techniques involving a rotational main movement

� Turning– work piece

rotation– tool translation

� Milling– tool- rotation– work piece-

translation

� Boring– tool rotation– tool translation

� Sawing– tool rotation– tool translation

main movement main movementmain movementmain movement

subsidiary movement sub. movement sub. movement sub. movement

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Breakdown of the techniques involving a translation al main movement

� broaching– multi teeth tool– feed due to tool geometry– high surface quality– high accuracy– high tool costs– inflexible

� planing– Cutting motion by work

piece– Tool feed– Stepwise, linear cutting

motion– Successive feed

movement– Machining of large, planar

areas

� shaping– Cutting motion by tool– workpiece feed– Stepwise, linear cutting

motion– Successive feed

movement– Machining of large, planar

areas

tool

work piece

track

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Modeling of Machining5

Hard machining4

Cutting processes with parallel translation3

Drilling2.3

Milling2.2

Turning2.1

Cutting processes with rotary motion2

Introduction1

Outline

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Modeling of Machining5

Hard machining4

Cutting processes with parallel translation3

Drilling2.3

Milling2.2

Turning2.1

Cutting processes with rotary motion2

Introduction1

Outline

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Example: rough turning

Source: Widia

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Example: finishing

Source: Widia

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Terms at the cutting edge

tool shank

cutting direction

major cutting edge S

major flank face Aα

minor flank face Aα‘

minor cutting edge S‘

rake face Aγ

corner radius

feed direction

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Definition of the tool cutting edge angle κκκκr

tool reference Plane Pr

tool orthogonal plane Po

tool cutting edge plane Ps

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Definition tool cutting edge angle κκκκr

trace of theworking plane Pf

tool

trace of the tool cutting edge plane PS

tool reference plane Pr

feed direction

κr

trace of the tool orthogonal plane Po

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Definition of the inclination angle λλλλs

working plane Pf

tool cutting edge plane PS

tool reference plane Pr

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Definition of the inclination angle λλλλs

tool

trace of the working plane Pf

tool cutting edge plane PS

major cutting edge S

trace of the tool reference plane Pr

cutting direction

λs+-

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Definition of the rake angle γγγγ

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Definition of the angles at the cutting edge

tool trace of the flank face plane Aα

trace of the rake face plane Aγ

trace of the tool back plane Pp

trace of the tool reference plane Pr

tool orthogonal plane P o

expected cutting direction

expectedfeed direction

γo

αo

βo

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Tool variants in longitudinal cylindrical turning

right hand side cutting

left hand side cutting

neutral

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Facing (DIN 8589-1: ON 3.2.1.1)

cross face turning

tool

workpiece

longitudinal face turning

workpiece

tool

cross parting off

tool

workpiece

Source: Sandvik Coromant

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Facing (DIN 8589-1: ON 3.2.1.1): cross / longitudin al face turning

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Facing (DIN 8589-1: ON 3.2.1.1): cross parting off

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Cylindrical turning (DIN 8589-1: ON 3.2.1.2)

longitudinal-cylindrical turning

tool

workpiece

cross-cylindrical turning

tool

workpiece

centreless rough turning

tool

workpiece

Source: Iscar, Ceratizit

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Threatening (DIN 8589-1: ON 3.2.1.3)

workpiece

tool

thread turning

workpiece

tool

chasing

workpiece

tool

tapping

thread turning (external) thread turning (internal)

Source: Garant, Seco, Ceratizit

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Profile turning (DIN 8589-1: ON 3.2.1.5)

trepanning grooving

tool

workpiece

cross-profile turning

workpiece

tooltool

workpiece

DIN 8589-1

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Hob turning (DIN 8589-1: ON 3.2.1.4)

tool

workpiece

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Contour turning (DIN 8589-1: ON 3.2.1.6)

copy turning

tool

workpiece

reference formed part

kinematic-contour turning

workpiece

toolgear

NC-contour turning

NCtool

workpiece

Source: Sandvik Coromant

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Internal turning

skimming

tool

workpiece

undercut

tool

workpiece

cut in

workpiece

tool

DIN 8589-1

Source: Iscar

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Internal turning tools

Source: Sandvik

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Modeling of Machining5

Hard machining4

Cutting processes with parallel translation3

Drilling2.3

Milling2.2

Turning2.1

Cutting processes with rotary motion2

Introduction1

Outline

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Milling processes DIN 8589-3

3.2.3

milling

DIN8589-3

3.2.3.1

slab / facemilling

3.2.3.2

circularmilling

3.2.3.6

formmilling

3.2.3.3

helicalmilling

3.2.3.4

hobbing

3.2.3.5

profilemilling

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Face milling (DIN 8589-3: ON 3.2.3.1)

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Face milling (DIN 8589-3: ON 3.2.3.1)

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Slab milling (ON 3.2.3.1): face- and peripheral mill ing

� face milling– Workpiece surface is generated by

face of the milling tool

� peripheral milling– Workpiece surface is generated by

peripheral surface of the milling tool

tool

workpiece

sP

pa

n

zf

fv

tool

workpiece

fv

zf

eacv

n

ϕ

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Up- and down milling

ae

fz

n

Fc

Ff

down milling

vc

vt

up milling

fz

n

FcFf

vtUp- and down milling

up milling part

down milling part

v t

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Tool-in-hand system: peripheral milling

workpiece

tool

trace of

trace of Pr

ps PP ≡

of PP ≡

EAc

E

ωωωω

−=°= 0

fv

zf

cv

ea

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Tool-in-hand system: face milling

trace of theentrance plane

workpiece

tool

trace of

trace of

trace of

trace of

n

fvoP

fP

ea

rPzf

par

κ

sP

pP

n

zf

νf

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Contact conditions and cutting edge geometry in fac e milling

ae

ae2

C

ae1

entry plane

vc

vf

ϕϕϕϕs

ϕϕϕϕ

n

fz

φ=0

tangential plane

cutting C-C

CϕϕϕϕA

-εεεεA

+εεεεE

n

view Atool

contact types

UT

Sb

γγγγp

K

S Sa V Va

tool cutting edge

A

fz

ap bB

plane B-B

B

n

2Da

arccos eii =ϕϕϕϕ

κsin

ab p=

rsinsinzfh κκκκϕϕϕϕϕϕϕϕ••=

(fz << D)

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Contact conditions depending on the radial and axia l rake angle

S - contact T - contact ST - contact

U - contact V - contact SV - contact

workpiecemillingcutter

insertdatum plane

S

T T

S

SVV

U

γγγγf > 0°

γγγγp > 0°

γγγγf > 0°

γγγγp < 0°

γγγγf > 0°

γγγγp = 0°

γγγγf < 0°

γγγγp < 0°

γγγγf < 0°

γγγγp > 0°

γγγγf = 0°

γγγγp > 0°

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Precision milling operations

ap1

ap2fz2

fz1

ap

ap

fz

fz

finish-milling

no. of teeth 10 to 60ap = 0.3 bis 1 mm

fz = 0.3 bis 0.5 mm

no. of teeth 1 bis 6

wide finish-milling

ap = 0.05 to 0.2 mm

fz = 0.5 bis 6 mm

fz2 = 2 to 5 mm

finish-milling with planing knivesand wide finishing cutting edgeno. of planing knives 20 to 30no. of wide finishing cutting edges 1 to 2finishing cutting edges

wide finishing cutting edges

ap1 = 0.5 to 2 mmfz1 = 0.1 to 0.3 mm

ap2 = 0.03 to 0.05 mm

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Circular milling (DIN 8589-3: ON 3.2.3.2)

workpiece

vf

apnw

nF

Mill

additional axial cutting edges radial cutting edges

workpiece

nF

nW

chipping space

nw

nF

vf

tool

tool

workpiece

Source: Walter

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a b c d e f

Helical milling (DIN 8589-3: ON 3.2.3.3)

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Hobbing (DIN 8589-3: ON 3.2.3.4)

-

FräserdrehungRadialvorschub

Tan

gen

tial

vors

chu

b

Werkraddrehung

Fräserdrehung

vc cutting speedfa axial feedfw hob feedradial feed

rotation of hobb

rotation of workpiece

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Different types of hobs

Monobloc gear hob Indexable insert hob

Fotos: Fette, Saazor, Saacke

� high revolutions of the mill

� short milling times

� short first cut length

� high cutting ability

� rough- and finish milling

� easily to re-sharpen

� large gearing

� no sharpening

� low accuracy

� only for rough milling

� large gearing

Roughing-finishing multi hob

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Profile milling (DIN 8589-3: ON 3.2.3.5)

profile milling cutter

DIN 8589-3

workpieceworkpiece

gang milling cutter

workpiece

Source: Sandvik Coromant, Ingersoll, ALESA AG

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Form milling (DIN 8589-3: ON 3.2.3.6)

form-profile milling

workpiece

tool

Source: Milltech, Dalscheid

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Modeling of Machining5

Hard machining4

Cutting processes with parallel translation3

Drilling2.3

Milling2.2

Turning2.1

Cutting processes with rotary motion2

Introduction1

Outline

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Drilling processes DIN 8589-2

3.2.2

drilling countersinking

reaming

DIN 8589-2

3.2.2.1

spot facing

3.2.2.2

centre drilling

3.2.2.3

tapping

3.2.2.5

profile drilling

3.2.2.6

form drilling

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Example of gun drilling

Source: Widia

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Example of gun drilling

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Criteria for drilling

� Material separation and reaming at the major cutting edge

� Plastic deformation at the chisel edge� Cutting speed drops down to zero in the centre

of the drill

� Chips are difficult to remove

� Unfavourable heat distribution at the interface

� Increased wear at the sharp-edged corner

� Reaming between leading lands and drilling wall

Reibung

Werkstück

Bohrwerkzeug

PlastischeVerformung

Stofftrennung

Reibung

f

n

frictionfriction

work-piece

drill

plastic deformation

material seperation

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Cutting conditions dependent on drill diameter

40° 30° 20° 10° 0° -10° -20° -30° -40° -50° -60°

20 10 0m/min

cutting speed vc

Rake angle γ; clearance angle αdr

ill r

adiu

s r

1

0

mm

4

6

8

10

9

7

5

mai

n cu

tting

edg

e

chis

el e

dge

vc γfe αfe

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Fundamental kinematics: centre drilling

β

γ

γf

ααxe

η

f/2f

cutting direction

effective directionfeed direction

cutting edge 1

cutting edge 2

η

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cutting part plunge (lettering point)

tapered shaft

flat tang

point length

cutting length

flute length

total length

cone length

plunge length

drill

dia

met

er d

nach DIN 8589-2

Geometry of the cutting part of a twist drill

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HW0.5 drill-point angle grain size

angle of twist major clearance angle

cutting material:construction dimensions

Geometry at the cutting edge of a twist drill

DIN 6539, Typ N

σ 118°

α: 10°: 35°

-DK: -

diameter d: 1 mm: 118°

10°δ:

K20

K 0.7 µm

Querschneide

Freifläche

Hauptschneide α

δ

chisel edge

flank face

major cutting edge α

δ

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pointed transverse

cutting edge

pointed cutting edge with corrected major cutting edge

cross-wise polish

pointed trans-verse cutting edge with

facetted cutting edge corners

point angle 180°with centre tip

cone shaped drill (basic

polish for form A-D)

Form A Form B Form C Form D Form E

Specific geometries of twist drills

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Twist drill for various materials

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Drilling processes I

centre drilling

tool

workpiece

feedmotion

primarymotion

gun drilling

feedmotion

primarymotion

workpiece

tool

tool

profile drilling

feedmotion

primarymotion

workpiece

tool

tapping

primarymotion

toolworkpiece

feedmotion

source: DIN 8589-2

drilling: Cutting with circular primary motion. The axis of rotation of the tool and ofthe produced internal area are identical. The direction of the feed has thedirection of this axis of rotation.

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Gundrilling

Source: Sandvik

drill bushing

SchaftHM-Kopf miteingeschliffenenFührungsleisten

cutting edge

shaft cemented carbidehead with indexable inserts

lubricationoutlet crimp

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Drilling processes II

tool

workpiece

feedmotion

primarymotion

countersinking

tool

workpiece

feedmotion

primarymotion

cylinder sinking

source: DIN 8589-2

sinking: Drilling for producing planes which are orthogonal to the axis of rotation orrotationally symmetric cone and form planes.

reaming: Bore up with a low undeformed chip thickness for producing better qualitiesof the surface.

tool

workpiece

feedmotion

primarymotion

reaming

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Fundamental kinematics: centre drilling

trace of

trace of

trace of

fv

oP

n

trace of

tool

work-piece

n

webthickness

major cutting edge

minor cutting edge

chisel edge trace of

trace of

sP

pP

fPrP

2

σκ =r Dap

⋅=2

1

zfh

bpa

σrP

cv

pP

rP

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Modeling of Machining5

Hard machining4

Sawing3.3

Broaching3.2

Shaping/ Planing3.1

Cutting processes with parallel translation3

Cutting processes with rotary motion2

Introduction1

Outline

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Modeling of Machining5

Hard machining4

Sawing3.3

Broaching3.2

Shaping/ Planing3.1

Cutting processes with parallel translation3

Cutting processes with rotary motion2

Introduction1

Outline

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Definitions and kinematics

planing/shaping:

Cutting with repeated parallel translation as primary motion and successivefeed motion which is orientated orthogonal to the primary motion.The kinematics of planing and shaping are identical. When the primary motion comes from the workpiece the process is called planing , when the primarymotion comes from the tool the process is called shaping .

shaping

primary motionat the tool

primarymotion at the

workpiece

planing

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Planing processes

finish planing

tool

workpiecefeedmotion

primarymotion

contour planing

feed motion

primarymotion

workpiece

tool

circular planing

feedmotion

primarymotion

workpiece

tooltool

profile planing

primarymotion

workpiece

feedmotion

source: DIN 8589-4

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Tool-in-hand system: planing

workpiece

tool

trace of

trace of

trace of

trace of

primarymotionat the workpiece

fvfP

oP

pP rP

sP

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Modeling of Machining5

Hard machining4

Sawing3.3

Broaching3.2

Shaping/ Planing3.1

Cutting processes with parallel translation3

Cutting processes with rotary motion2

Introduction1

Outline

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Internal broaching tools (schematic)

end pieceA

shank way roughing- finishing- calibrating part(f z=0)

fzt B bαααα01 αααα01

αααα02

detail A detail Bαααα02 clearance angle

αααα01 chamfer inclination

γγγγ0 rake angle

γγγγ0000

bαααα01 width of chamber

t division

fz inclination

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Broaching processes I

source: DIN 8589-5

workpiece

tool

primarymotion

feedmotion

plane broaching

workpiece

tool

external broaching

primarymotion

feed motion

workpiece

primarymotion

tool

feedmotion

internal broaching

broaching: Cutting with a tool with more than one flute. The flutes are orientated one afteranother with the stepping of the undeformed chip thickness. The feed motion issubstituted by the stepping. The last flutes of the tool produces the desiredprofile of the workpiece. After one run, the workpiece is ready and the surfacefinished.

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Broaching processes II

source: DIN 8589-5

workpiece

toolprimarymotionfeed

motion

profile broaching

workpiece

tool

primarymotions

helical broaching

workpiece

tool

primarymotions

cylindrical broaching

feedmotion

workpiece

tool

initial shape ofthe workpiece

end shape ofthe workpiece

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Tool-in-hand system: internal broaching

primarymotion

feed motion isrealized with thestepping flutes

trace of

trace of

fv

tool

workpiece

tool and workpiecesps PP ≡

rP

of PP ≡

zf⋅4

pa

zt

cv

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Modeling of Machining5

Hard machining4

Sawing3.3

Broaching3.2

Shaping/ Planing3.1

Cutting processes with parallel translation3

Cutting processes with rotary motion2

Introduction1

Outline

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Sawing processes

source: DIN 8589-6

workpiece

tool

primarymotion

feedmotion

hack sawing

tool

workpiece

feedmotion

primarymotion

circular sawing workpiece

tool

feedmotion

primary motion

band sawing

sawing: Cutting with circular motion or parallel translation as primary motion. TheTools have more than one flute. The depth of cut is low and the primarymotion comes from the tool.

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Terms and cutting part geometry of the sawing belt

tooth head

width

back of belt

cutting part

base of agear tooth

t

H

g0b0R

a0

tooth gap

(chip space )

workpieceworking plane

ae

fz90ove

vch

belt saw

vc cutting speed

ve operating speed

fz tooth feed

ae width of cut

t tooth division

R base radius

H tooth height

tip of tooth

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Tool-in-hand system: hack sawing

trace of

trace of

tool

workpiece

trace of

trace of

fv

primary motion

zf

feedmotion

ps PP ≡of PP ≡

rP

rP ps PP ≡

of PP ≡

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Modeling of Machining5

Hard machining4

Cutting processes with parallel translation3

Cutting processes with rotary motion2

Introduction1

Outline

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Hard machining with geometrically defined cutting e dgesTechniques

� turning

� milling

� broaching

Cutting materials

� ultra fine grained carbides

� ceramics

� PCBN

Technological specialties

� cutting process is conducted by a single or a few cutting edges

� strong relation between the condition of single cutting edges and the surface rim zone of the workpiece, because the materials are hard and thus the tools posses a high wear risk

� risk of white layers

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Hardening steel leads to mechanically strong parts

Soft

Material volume: 100 %Material volume: approx. 103 %non-uniform strain anddistortion

Strain e

Str

ess

s

Micro structure: ferrite

Hardness: 20 - 35 HRC

Strain e

Str

ess

s

Micro structure:martensite

Hardness: 55 - 65 HRC

=> Final cut necessary to achieve high accuracy in f orm and size,small and medium parts need to be oversized by appr ox. 0.3 - 0.5 mm

HardHardening /Tempering

Mechanically strong steel parts need to be hardened / tempered

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Cams shaft

Bearing rings

Gears

Slipping load(e.g. contact with bucket tappet)

Rolling load(contact with rollers)

Rolling load(Contact with partner gear)

Slipping load (Contact with synchronising ring)

Micro slipping(Contact with shaft)

Bending load (at tooth ground)

Typical parts for hard machining

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Hard machining, turning and grinding

� Hard machining can be realised bydefined and undefined machining principles.

� Hardened steel can only be cut defined if the material in front of the cutting tip is heated and softened by the process itself.

� This leads to special requirements for the cutting material and the press design.

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Application for Precision Hard Turning

10 %

20 %

30 %

40 %

50 %

60 %

70 %

80 %

90 %

100 %

10 %

20 %

30 %

40 %

50 %

60 %

70 %

80 %

90 %

100 %Machining time Machining Cost

Grinding Hard Turning Grinding Hard Turning

Material: X210CrW12hardened (63 HRC)

Machining: Hard turning of theprofile

Part: Precision profile rollerO 150 mm

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Modeling of Machining5

Hard machining4

Cutting processes with parallel translation3

Cutting processes with rotary motion2

Introduction1

Outline

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Force calculation: time functionSubstitution of the empirical force equation propos ed by Kienzle with the technical terms:

imii hbkF −⋅⋅= 1

1.1

polar coordinatenumber of teeth

diameter of the tool

equation proposed bySalomon or Kienzle

source: Diss. Rehse

discretisation of the equation:

basement for modeling

Question: What is the angle ωωωω?

( )im

r

c

f

r

pii

vz

vDakF

⋅⋅

⋅⋅⋅

⋅⋅≈1

1.1 sinsinsin

κωπ

κ

( )im

rc

c

f

r

pii

D

dtv

vz

vDakdF

⋅⋅⋅⋅

⋅⋅⋅⋅≈

1

1.1 sin2

sinsin

κπ

κ

tvb c ⋅=)D

b)⋅= 2ω

ωκ sinsinmax ⋅⋅≈ rzfh

r

pab

κsin=

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Force calculation: technical terms

discretisation of the equation:

discrete time function

Solving the equation fordiscrete times

discrete force components

)(dtdFi

transformation of theforce components intothe x- and y- direction

addition of the forcecomponents in x- andy- direction separately

forc

e in

x /

N

time / sec

measuredcalculated

The same procedurefor the other flutes!

( )im

rc

c

f

r

pii

D

dtv

vz

vDakdF

⋅⋅⋅⋅

⋅⋅⋅⋅≈

1

1.1 sin2

sinsin

κπ

κ

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Penetration calculation: peripheral milling

vector field for representation the tool

vector field for representation the workpiece

feedvelocity

matrix model for the penetration calculation

data of the machine tool data of the workpiecedata of the tool

thickness of cut h width of cut b

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Thank you for your attention!!

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Modeling of Machining5

Hard machining4

Cutting processes with parallel translation3

Cutting processes with rotary motion2

Introduction1

Outline

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Modeling of Machining5

Hard machining4

Cutting processes with parallel translation3

Cutting processes with rotary motion2

Introduction1

Outline

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Process classification

source: DIN 8589-0

Manufacturing Processes

1

primary shaping

2secondaryshaping /forming

3

cutting

4

joining

5

coating

6changingmaterial

properties

3.2cutting

3.2.1

turning

3.2.2drilling

reaming

3.2.3

milling

3.2.4planingshaping

3.2.5

broaching

3.2.6

sawing

3.2.7filing

rasping

3.2.8

brushing

3.2.9scrapingchiselling

rotary motion parallel translation

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Evaluation

Attend:� knowledge of the complete workpiece design (angel ω)� if the information is not available the modeling cannot success!

� general model� possibility to use

general software� possibility to expand

with dynamic terms� mathematical formulation

advantages

� no direct materialinformation

disadvantage

This information is contained in thespecific force parameter!


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