Segmentspanbildung, Werkzeugverschleiß, Randschichtzustand und Bauteileigenschaften: Numerische Analysen zur Optimierung des Zerspanungsprozesses am Beispiel von Ti-6Al-4V

Im Rahmen der Arbeit werden Simulationsmodelle vorgestellt, die ausgehend von Zerspanungssimulationen über die Simulation des Werkzeugverschleißes sowie der resultierenden Bauteilzustände und -eigenschaften eine ganzheitliche Prozessoptimierung ermöglichen. Diese zeigt, dass bei gezielter Prozessparameterwahl eine ideale Kombination aus Werkzeugstandzeit und resultierender Bauteileigenschaften erzielt werden kann. Mittels zerspanungstechnologischer Experimente werden die Modelle validiert

Pbf-lb process-induced regular cavities for lightweight alsi10mg structures

In powder bed fusion with laser beam (PBF-LB), two process-induced defects by pore formation are known: local spherical pores by the keyhole effect and geometrically undefined pores caused by lack of fusion. Both pore types are heterogeneously distributed and can be used for lightweight or damping design applications. The achievable porosity is limited to around 13%. This article presents a novel process-controlled method enabling the targeted and reproducible manufacturing of solid parts with regularly distributed cavities, currently up to 60% porosity in AlSi10Mg, using the balling effect. This eliminates the need for time-consuming digital pre-processing work

Effects of Different Levels of Abstraction Simulating Heat Sources in FEM Considering Drilling

AbstractThis paper presents a comparison of three different methods of simulating heat sources in 3D-FEM-simulations with various levels of abstraction for drilling. The investigated methods are modelled and evaluated with respect to calculation time and accuracy of simulated temperature fields and phase transformations. Results are showing a significant variance of the maximum temperature and temperature distribution for the three different heat sources although the same amount of energy is used in the simulation model. According to the longest simulation time the most detailed heat source provides a realistic temperature distribution