Development of a simulation based method for a load dependent optimisation of cemented carbide tools for nickel-base alloys - Variable micro geometry along the cutting edge

该知识转移项目提案基于基础研究项目：热机械载荷和磨损行为建模，以优化硬质合金麻花钻。前一个项目的重点是三维有限元模拟的芯片形成的切削刃准备的影响，在钻削过程中的工具负载的预测。空间分辨率低、计算时间长，给模拟分析带来困难。因此，提出了一种替代模式。进行正交切削的这些模拟，其代表在钻孔工具的第一主切削刃上的不同正交切削。该方法具有空间分辨率高、计算时间短等优点，在镍基合金的钻削加工中具有一定的应用和推广价值。这包括通过使用实验设计来考虑局部工艺条件，如钻孔中的半径依赖性切削速度。刀具磨损采用了切向力模型。切削刃的参数化描述可用于刀具磨损的统计建模，其为参数值的每种可能组合提供磨损预测。此外，统计模型被用来找到切削刃参数，使刀具磨损最小化。这种方法在这里扩展到铣削过程中，其中具有特征变化的未切屑厚度在一个单一的刀具旋转。此外，开发了一种测量制备的切削刃的方法。最后，优化的工具相比，标准的工具在实验测试。

This knowledge transfer project proposal is based on the fundamental research project: Modelling of the thermo-mechanical loads and wear behavior for optimisation of cemented carbid twist drills. The former project focused on the three-dimensional FE-simulation of chip formation for the prediction of the influence of the cutting edge preparation on the tool load during drilling processes. The low spatial resolution and long calculation times lead to difficulties during the analysis of the simulation. Therefore, an alternative model was proposed. These simulations of orthogonal cutting are carried out, which represent different orthogonal cut on the first primary cutting edge of a drilling tool. This technique offered the advantage of higher spatial resolution and shorter calculation times and should be applied and extended for drilling and milling of nickel-base alloys. This includes the consideration of local process conditions like the radius-dependent cutting speed in drilling by using design of experiments. The tool wear is simulated by the model of Usui. The parametric description of the cutting edge can be used for the statistical modelling of the tool wear which provides a wear prediction for every possible combination of parameter values. Furthermore, the statistical model is used to find cutting edge parameters which minimize the tool wear. This approach is extended here to milling processes, which have characteristic variations of the uncut chip thickness during a single tool rotation. Furthermore, a method is developed for measuring prepared cutting edges. Finally, optimized tools are compared to standard tools in experimental tests.