Investigation of the operational behaviour of binderless cemented carbide for high-precision milling of an aluminium alloy containing silicon and magnesium

无粘结剂硬质合金高精度铣削含硅镁铝合金的操作行为研究

• 批准号: 506652301
• 负责人: Professor Dr.-Ing. Eckart Uhlmann
• 金额: --
• 依托单位: Fachgebiet Werkzeugmaschinen und Fertigungstechnik
• 依托单位国家: 德国
• 项目类别: Research Grants
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/506652301?language=en
• 关键词: Investigation; operational; behaviour; binderless; cemented

Tool and mould making is one of the most important industrial sectors of the manufacturing industry in Germany. Due to the growing technical development, the tool and mould making is subject to continuously increasing demands on shape accuracies as and surface roughness values of the manufactured components. The aluminium-magnesium-silicon alloy (AlMgSi1) is the most commonly used material for the pre- and pilot-series up to the first phase of series production of manufactured injection moulds. For this purpose, milling is a suitable manufacturing process for the production of injection moulds consisting of the AlMgSi1-alloy. The state of the art shows that uncoated cemented carbide tools are still used for the roughing process. These tools consist of a binder phase made of cobalt, which leads to considerable tool wear due to a temperature-induced removal of the binder phase. The structural cohesion of the cutting material is reduced, resulting in lower shape accuracy as and higher surface roughness values as well as a high economic load. In addition, the finishing process will realised with cost-intensive cutting tools made of diamonds, which results in high process costs cp. For this reason, the operational capability of the binderless cemented carbide as an innovative cutting material will be analysed. Due to the hardness H as well as the micro-structure properties, the process capability and the applicability will be affected. For this purpose, detailed scientific studies will be carried out. The objective of the research work is the identification of significant wear characteristics of the binderless cemented carbide tools, the development of a suitable process technology for the preparation of the cutting edges as well as the analyse of the operational capability for the cutting of the AlMgSi1-alloy. To realise the research project with regard to the scientific research hypothesis, the specific material properties will be characterised and analysed. Based on this, detailed investigations for the tool wear will be carried out to determine the significant wear characteristics of the binderless cemented carbide tools. Due to a high stability and the implementation of complex geometric structures, two-edge ball end mills will be applied. For the preparation of the grinded manufactured cutting edges to reduce the maximum chipping of the cutting edge RS,max, an immersed tumbling process will be carried out, which leads to improved conditions for the subsequent machining tests. Based on this, the operational capability of the binderless cemented carbide tools and the wear behaviour depending on the path length lc will be analysed to evaluate the scientific research hypothesis as well as to enable high tool life times TSt and an economical machining of the AlMgSi1-alloy.

工具和模具制造是德国制造业最重要的工业部门之一。由于技术的不断发展，工具和模具制造对所制造部件的形状精度和表面粗糙度值的要求不断提高。铝-镁-硅合金（AlMgSi 1）是预试和中试系列直至注塑模具批量生产第一阶段最常用的材料。为此，铣削是用于生产由AlMgSi 1合金组成的注塑模具的合适的制造工艺。现有技术表明，未涂覆的硬质合金刀具仍用于粗加工工艺。这些工具由钴制成的粘结相组成，由于温度引起的粘结相的去除，这导致相当大的工具磨损。切削材料的结构内聚性降低，导致较低的形状精度和较高的表面粗糙度值以及高经济负荷。此外，精加工过程将使用由金刚石制成的成本密集型切割工具来实现，这导致高工艺成本cp。为此，将分析无粘结剂硬质合金作为创新切削材料的操作能力。由于硬度H以及显微组织特性，工艺能力和适用性将受到影响。为此，将进行详细的科学研究。研究工作的目的是识别无粘结剂硬质合金刀具的显著磨损特性，开发用于制备切削刃的合适工艺技术以及分析用于切削AlMgSi 1合金的操作能力。为了实现关于科学研究假设的研究项目，将对特定的材料特性进行表征和分析。在此基础上，对无粘结剂硬质合金刀具的磨损进行了详细的研究，以确定无粘结剂硬质合金刀具的显著磨损特征。由于高稳定性和复杂几何结构的实现，两刃球头米尔斯铣刀将被应用。为了准备经研磨的制造的切削刃以减少切削刃RS，max的最大碎裂，将执行浸没滚磨工艺，这导致后续机加工测试的改善条件。在此基础上，将分析无粘结剂硬质合金刀具的操作能力和取决于路径长度lc的磨损行为，以评估科学研究假设，以及实现高刀具寿命TSt和AlMgSi 1合金的经济加工。