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Fundamental analysis of the cutting edge micro-geometry in orthogonal machining of unidirectional Carbon Fibre Reinforced Plastics (CFRP)
(2018)Procedia CIRP ~ 8th CIRP Conference on High Performance Cutting (HPC 2018)Machining of carbon fibre reinforced plastics (CFRP) is closely related to strong abrasive tool wear and represents a significant process challenge due to its anisotropic material structure and brittle fracture behavior. Furthermore, machining of unidirectional CFRP material shows a significant increase in process forces due to tool wear effects, resulting in a changing micro-geometry of the cutting edge. This research work aims to give ...Conference Paper -
Improved stability predictions in milling through more realistic load conditions
(2018)Procedia CIRP ~ 8th CIRP Conference on High Performance Cutting (HPC 2018)In this paper, the combined influence of the load condition and the spindle speed on the tooltip dynamics of a five-axis milling machine with dominant spindle modes is evaluated. A constant preload is applied through axially and radially arranged permanent magnets while the dynamic excitation of the rotating dummy tool takes place by a force impact. The structures response is measured with non-contact sensors and Frequency Response Functions ...Conference Paper -
Cutting Process Tribometer Experiments for Evaluation of Friction Coefficient close to a CFRP Machining Operation
(2017)Finishing operations of Carbon Fibre Reinforced Polymers (CFRP), such as drilling or milling are known to generate heavy tool wear. Consequently, ultra-hard cutting materials like diamond-coated carbide tools or PCD-tools are utilised. To further improve the lifetime of these tools, it is recommended to adjust the tool geometry, process parameters and coating to the relevant application. Usually, the process optimisations base on knowledge ...Conference Paper -
A study of the interaction between coolant jet nozzle flow and the airflow around a grinding wheel in cylindrical grinding
(2017)Procedia CIRP ~ 16th CIRP Conference on Modelling of Machining Operations (16th CIRP CMMO)A grinding wheel rotating at high circumferential speed induces a boundary-layer airflow which possibly can detain the coolant from submerging into the grinding zone, in order to prevent thermal damage. To study the profile of the airflow, general laws of fluid dynamics are applied and the analytical results compared with results from CFD simulations. These are used to investigate the interaction of the coolant with the grinding wheel ...Conference Paper -
Post-Coating Treatment of Cutting Edge for Drilling Carbon Fibre Reinforced Plastics (CFRP)
(2016)Procedia CIRP ~ 7th HPC 2016 – CIRP Conference on High Performance CuttingDrilling of highly abrasive carbon fibre reinforced plastics (CFRP) requires carbide tools with geometrical highly adaptable tool geometries andwear resistant diamond coatings. To counteract the tradeoff between long tool lifetime by preferably thick diamond layers leading to largecutting edge radii (bluntness), and the sharpest possible cutting edge to generate flawless machining qualities, the following ...Conference Paper -
EDM Drilling and Shaping of Cooling Holes in Inconel 718 Turbine Blades
(2016)Procedia CIRP ~ 18th CIRP Conference on Electro Physical and Chemical Machining (ISEM XVIII)Machining capabilities of modern EDM drilling machines for drilling cooling holes and diffusers in turbine blades are described. For improving the process capability and machining efficiency of aerospace alloys, drilling of cooling holes and formation of diffusers can be combined into a single process by using the same electrode for both processes. Experimental results of material removal rate, relative tool wear and surface integrity for ...Conference Paper -
Success Story Cutting
(2016)Procedia CIRP ~ 7th HPC 2016 – CIRP Conference on High Performance CuttingCutting technologies are the engines behind manufacturing. Without cutting, none of our modern products would ever been put into service. Developing new materials directly needs research for process windows in cutting. Huge engineering efforts brought cutting in the position where it is today and despite all rumors trying to declare, that cutting is outdated or cutting research is finished it is still a vital field of research and prone ...Conference Paper -
Springback in metal cutting with high cutting speeds
(2015)Procedia CIRP ~ 15th CIRP Conference on Modelling of Machining Operations (15th CMMO)In metal forming springback is a widely researched topic. It is generally referred to as the change of part shape that occurs upon removal of constraints after forming. In cutting this also occurs but on a much smaller level. Literature [1], [2], [3] shows divers results for mostly static or quasi-static experiments leading to simulations without velocityinfluence. Experiments done at IWF of ETH Zürich provide results with cutting speeds ...Conference Paper -
Chip root analysis after machining carbon fiber reinforced plastics (CFRP) at different fiber orientations
(2014)Procedia CIRP ~ 6th CIRP International Conference on High Performance Cutting, HPC2014Machining carbon fiber reinforced plastics (CFRP) is currently being heavily investigated. The main drivers come from the aviation and automotive industry. Current drilling and milling tool geometries exhibit immense wear resulting in the damage of the work piece. Detailed understanding of chip formation mechanisms when machining CFRP is paramount and enables the optimization of tool geometries in terms of tool lifetime and work piece ...Conference Paper -
Tool Life Time Extension with Nano-crystalline Diamond Coatings for Drilling Carbon-fibre Reinforced Plastics (CFRP)
(2014)Procedia CIRP ~ New Production Technologies in Aerospace Industry - 5th Machining Innovations Conference (MIC 2014)Carbon fibre reinforced plastics (CFRP) are delicate to machine as the material is highly abrasive and tends to show multiple workpiece damages like delamination, fibre pull out, uncut fibres and burnt matrix material. In result machining CFRP requires on the one hand tools which can withstand the massive wear, on the other hand geometrical highly adaptable tools to produce flawless workpieces. Diamond coated solid carbide tools can provide ...Conference Paper