Optimized wobble milling to increase process efficiency and machining quality when machining CFRP

该项目的目标是与一个工业合作伙伴合作，优化现有的摆动铣削工艺，以提高加工效率和改善加工质量。除了摆动铣削之外，本项目还将为加工纤维增强塑料(FRP)的刀具设计提供更多的见解。该项目的子目标是在钻削玻璃钢时通过优化的摆动铣削工艺来提高工艺效率和减少损害，开发一个模拟程序，用于考虑材料设置的多轴加工工艺的工艺设计和刀具几何形状的确定，以及创建用于工业工艺设计的程序。与目前的摆动铣削相比，优化后的摆动铣削应能显著提高效率，这是由新的设置引起的，同时还改善了加工质量。工艺步骤由三步减少到两步，保证了效率的提高。通过这种方式，降低了摆动磨削的工艺复杂性和加工时间。工艺开发的主要挑战在于设计和确定工具的各个几何参数之间的相互作用。在第一道工序中加工顶层时，需要将加工力向下引导到工件的内部，从而平衡几何要素。在第二个加工步骤中，需要将底部的加工力向上引导到工件的内部。对连续纤维增强的不同层状结构的研究，确保了所开发工艺的有效可用性的推广。开发模拟程序的挑战在于过程运动学的描述、材料参数的实现和所开发的过程力模型。通过该程序，将创建一个新的模块，在该模块上可以根据不同的要求调整工艺设计。模拟对于工具和工艺设计是必要的，并允许将开发的工艺传播到工业环境中。在计划的项目中，可以获得大量关于玻璃钢加工的知识。除了对该工艺进行验证外，还将开发一种在工业环境中使用优化摆动铣削的方法。因此，这一研究项目为可持续和经济的生产做出了重大贡献，并为技术应用提供了直接的好处。

The objective of this project is to optimize the existing wobble milling process to increase process efficiency and improve the machining quality in cooperation with an industrial partner. In addition to wobble milling further insights for tool design for machining fiber reinforced plastics (FRP) will be generated in this project. The subgoals of this project are to reach an increase of process efficiency and a reduction of damage with the optimized wobble milling process when drilling FRP, to develop a simulation program for process design and determination of tool geometry for multiaxial machining processes considering the material setup as well as to create a procedure for industrial process design. The optimized wobble milling should allow significant increase in efficiency in comparison to the present wobble milling caused by the new setup at additionally improved machining quality. The increase of efficiency will be ensured with the reduction from three to two process steps. In this way the process complexity as well as processing time for wobble milling decreases. The primary challenges for process development consist in the design and determination of interactions between the individual geometry parameters of the tool. The geometrical elements need to be balanced in a way that when machining the top layer in the first process step the process force needs to be directed downwards to the inner of the workpiece. In the second process step the process force at the bottom side needs to be directed upwards to the inner of the workpiece. The investigations of different layer structures with continuous fiber reinforcement ensure the spread of effective usability of the developed process. The challenge for the development of the simulation program consists in the description of the process kinematic, the implementation of material parameters and the developed process force models. With this program a new module will be created at which the process design can be adjusted to various requirements. The simulation is necessary for tool and process design and allows a dissemination of the developed processes to the industrial environment. Within the planed project a significant gaining knowledge for machining of FRP can be reached. In addition to the validation of the process an approach for the use of the optimized wobble milling in industrial environment will be developed. Therefore this research project provides a substantial contribution for a sustainable and economic production and offers a direct benefit for technical applications.