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

该项目的目标是与工业合作伙伴合作，优化现有的摆动铣削工艺，以提高工艺效率并改善加工质量。除了摆动铣削，该项目还将对加工纤维增强塑料（FRP）的刀具设计产生进一步的见解。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提高工艺效率，减少损坏，开发一个模拟程序，用于工艺设计和确定多轴加工工艺的刀具几何形状，考虑材料设置，以及创建一个工业工艺设计程序。优化后的摆动铣削与目前由新装置引起的摆动铣削相比，应能显著提高效率，同时提高加工质量。效率的提高将通过将三个工艺步骤减少到两个工艺步骤来保证。通过这种方法，可以降低摆动铣削的加工复杂度和加工时间。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。几何元素需要以一种方式进行平衡，即当在第一个加工步骤中加工顶层时，加工力需要向下定向到工件的内部。在第二个过程步骤，在底部的过程力需要向上定向到工件的内部。对连续纤维增强的不同层状结构的研究保证了所开发工艺的有效可用性的推广。开发仿真程序的挑战在于过程运动学的描述、材料参数的实现和开发的过程力模型。有了这个程序，将创建一个新的模块，在这个模块中，工艺设计可以根据各种要求进行调整。仿真对于工具和过程设计是必要的，并且允许将开发的过程传播到工业环境中。在计划的项目中，获得玻璃钢加工的重要知识。除了对工艺进行验证外，还将开发优化后的摆动铣削在工业环境中的应用方法。因此，该研究项目为可持续经济生产做出了重大贡献，并为技术应用提供了直接效益。

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.