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

工具和模具制造是德国制造业中最重要的工业部门之一。随着技术的不断发展，刀具和模具制造对被制件的形状精度和表面粗糙度的要求不断提高。铝镁硅合金（AlMgSi1）是制造注塑模具的预生产和中试生产阶段最常用的材料。为此，铣削是生产由almgsi1合金组成的注塑模具的一种合适的制造工艺。目前的技术水平表明，未涂层硬质合金刀具仍用于粗加工。这些工具由钴制成的粘结相组成，由于温度导致粘结相的去除，导致工具磨损严重。切削材料的结构凝聚力降低，导致较低的形状精度和较高的表面粗糙度值以及较高的经济负荷。此外，精加工过程将使用由钻石制成的成本密集型切割工具来实现，这导致了高工艺成本cp。因此，将分析无粘结剂硬质合金作为一种创新切割材料的操作能力。由于硬度H和显微组织性能的不同，会影响加工性能和适用性。为此，将进行详细的科学研究。研究工作的目的是确定无粘结剂硬质合金刀具的显著磨损特性，开发合适的切削刃制备工艺技术，并分析切削almgsi1合金的操作能力。为了实现关于科研假设的研究项目，将对具体的材料特性进行表征和分析。在此基础上，开展刀具磨损的详细研究，确定无粘结剂硬质合金刀具的显著磨损特征。由于其高稳定性和复杂几何结构的实现，双面球立铣刀将被应用。为了制备研磨后的成品切削刃，以减小切削刃RS max的最大切屑，将进行浸入式翻滚工艺，从而改善后续加工试验的条件。在此基础上，将分析无粘结剂硬质合金刀具的操作能力和随路径长度lc的磨损行为，以评估科学研究假设，并实现高刀具寿命TSt和经济加工almgsi1合金。

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.