Experimental and simulative investigations on machining aluminium lightweight structures

Biermann, D.^{1, a}; Engbert, T.^{1, b}; Grünert, S.^{1, c}; Hammer, N.^{1, d}

1)

Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 301, 44227 Dortmund

a) biermann@isf.de; b) engbert@isf.de; c) gruenert@isf.de; d) hammer@isf.de

Kurzfassung

In industrial practice, the machining of lightweight profiles is associated with different problems. During conventional machining operations, process stability is often affected by material-dependent adhesion at the cutting edges. Due to adhesion, the quality of surfaces and bore-holes as well as the reliability of the machining operation often become inadequate. The accurate machining of thin-walled profiles is exceptionally difficult due to their elastic structure and their tendency to oscillate in the frame structure. During the machining of extruded steel wire reinforced light-metal-matrix profiles, tool wear is an additional crucial factor. The potential and limitations of process design for high quality bore-holes produced by drilling and circular milling of conventional and steel-wire reinforced aluminium profiles are presented in this paper. Both, experimental research and simulation-based analyses form the basis of this paper.

Schlüsselwörter

aluminium, composite, lightweight construction, drilling, circular milling, orbital milling, simulation, FEA, finite element analysis

Veröffentlichung

International Journal of Machining and Machinability of Materials, 4 (2008) 4, S. 345-360