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Optimizing the feed velocity of NC-tool paths

Optimierung der Vorschubgeschwindigkeit von NC-Werkzeugverfahrwegen
: Uhlmann, E.; Mattes, A.

Micari, F.; Filice, L. ; University of Calabria, Rende:
10th CIRP International Workshop on Modeling of Machining Operations. Proceedings : August 27-28, 2007, Reggio Calabria, Italy
Rende: University of Calabria, Department of Mechanical Engineering, 2007
ISBN: 978-88-95267-04-3
International Workshop on Modeling of Machining Operations <10, 2007, Reggio Calabria>
Fraunhofer IPK ()
NC-Steuerung; Werkzeug; Weg; Vorschubgeschwindigkeit; Optimierung; Simulation; Fräsen; Materialabtragung; mechanische Belastung; Wärmebelastung; Werkzeugverschleiß; Inconel; Bearbeitungszeit; Experiment; Schneide; Kostensenkung

In recent years various simulation tools with which the feed velocity can be optimized have been developed for an efficient milling of complex components. Hitherto, the material removal rate has been calculated and the respective commands in the NC-program have been adapted. Further approaches include the mechanical tool load which is determined analytically. Equally, the material removal rate has a significant influence on the thermal tool load. This paper describes an approach with which both the mechanical as well as the thermal load is calculated for a given NC-tool path. If a certain value is overstepped, the feed velocity is reduced respectively. As a result the feed velocity is optimally adjusted to the engagement conditions. In addition, the calculation of the wear is carried out. In cutting experiments with Ck45 and Inconef718 it was possible to reduce the primary processing time significantly. Furthermore, regarding Ck45 it was possible to predict the wear with a small fault tolerance. Concerning that NC-speed already assures a maximum economy of time for machining of 20 % compared to a not optimized NC-Code, this clarifies the achieved results. Against this background it seems not negative at all, that the tool wear is not reduced through the integration of technology inside the optimization, Furthermore it has to be stated positively that the tool wear does not rise despite the significant decreased machining time. Another objective of the cutting experiment was the verification of the calculated tool wear with the measured one. It may declared, that the results are in good agreement for the fourth and the fifth section of the cutting edge. However, generally the cutting experiment shows that a prediction of the tool wear is possible with a sufficient accuracy for deciding if a tool change is necessary or not. Thus the achieved benefit may help to improve the process reliability and reduce the tool costs.
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