Stochastic Modeling of the Interaction of Tool Wear and the Machining Affected Zone in Nickel-Based Superalloys and Application in Dynamic Stability
Final Report Abstract
The main objective of this research project was to determine models for an existing simulation system for optimizing the machining of nickel-based superalloys. A detailed analysis of different process parameters on the wear development and the resulting process forces was conducted in fundamental investigations. Based on this, a multi-dimensional model could be derived describing the stochastically occurring tool wear progression. By decoupling the tool wear from the milling process using artificially generated wear states, analysis of orthogonal cutting tests contributed to deriving new models for a geometrical-physical simulation system. A new tool model was developed taking topographical changes of worn inserts using a structured grid into account. Herewith, the simulation system could be extended allowing for an efficent calculation of wear-dependent process forces in milling nickel-based superalloys. Furthermore, in order to improve the vibration behavior of milling processes, a method for generating stochastic tool paths was presented. Additionally, an automated procedure for characterizing the flank wear area was developed using an imageprocessing algorithm. Regarding future research questions, a methodology has been developed with which segmentation of digitized inserts and a subsequent FE analysis could provide a qualitative evaluation of weardependent process forces. This method offers the possibility to determine a range of different force coefficients for varying cutting edge geometries instead of determining individual force coefficients for one tool-material combination.
Publications
- “Fundamental investigations on wear evolution of machining Inconel 718.” In: Procedia CIRP 99 (2021), pp. 171–176
N. Potthoff and P. Wiederkehr
(See online at https://doi.org/10.1016/j.procir.2021.03.024) - “Modeling of cutting forces in trochoidal milling with respect to wear-dependent topographic changes.” In: Production Engineering 15.6 (2021), pp. 761–769
J. A. Bergmann, N. Potthoff, T. Rickhoff, and P. Wiederkehr
(See online at https://doi.org/10.1007/s11740-021-01060-4) - “Development of a Contrived Tool Wear Method in Machining.” In: ASME International Mechanical Engineering Congress and Exposition. Vol. 85567. American Society of Mechanical Engineers. (2022), V02BT02A059
T. J. Grimm, N. Potthoff, N. A. Kharat, L. Mears, and P. Wiederkehr
(See online at https://doi.org/10.1115/IMECE2021-70454) - “Stability Performance of a Stochastic Toolpath in Machining.” In: ASME International Mechanical Engineering Congress and Exposition. Vol. 85550. American Society of Mechanical Engineers. (2022), V02AT02A035
T. J. Grimm, N. A. Kharat, N. Potthoff, L. Mears, and P. Wiederkehr
(See online at https://doi.org/10.1115/IMECE2021-69264) - “Experimental and simulative analysis of an adapted methodology for decoupling tool wear in end milling.” In: Procedia Manufacturing Letters 33:380-387 (2022)
N. Potthoff, A. Agarwal, F. Wöste, J. Liß, L. Mears, and P. Wiederkehr
(See online at https://doi.org/10.1016/j.mfglet.2022.07.050)
