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PublicationAn optimization approach for a milling dynamics simulation based on Quantum Computing( 2024-02-01)
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PublicationPreparation of Papers for IFAC Conferences & Symposia: Adaptive fixture system for reducing machining distortion caused by residual stresses in milling( 2022)Machining distortion caused by residual stresses is one of the major challenges in the production of thin-walled monolithic parts, which are widely used in the aerospace industry. The relevant influencing factors include the selected process parameters, the machining sequence as well as the used fixture system. This paper presents an adaptive fixture system for reducing machining distortion caused by residual stresses in milling. To validate the advantage of this system, machining distortion experiments are conducted on monolithic parts made of Ti-6A1-4V using a conventional and the adaptive fixture system.
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PublicationKnowledge-Based Process Design Optimization in Blisk Manufacturing( 2022)The manufacturing process of blade-integrated disks (blisks) represents one of the most challenging tasks in turbomachinery manufacturing. The requirement is to machine complex, thin-walled blade geometries with high aspect ratios made of difficult-to-cut materials. In addition, extremely tight tolerances are required, since the smallest deviations can lead to a reduction in efficiency of the blisk in the later use. Nowadays, the ramp-up phase for the manufacturing of a new blisk is time and cost-intensive. To find a suitable manufacturing process that meets the required tolerances of the blisk, many experimental tests with different process parameters and strategies are necessary. The used approach is often trial and error, which offers limited testing opportunities, is time-consuming and waste of resources. Therefore, the objective of this paper is to develop a knowledge-based process design optimization in blisk manufacturing. For this purpose, this paper picks up the results from our previous work. Based on these results, an experimental validation of the two process design tasks “number of blocks” and “block transition” is conducted. As part of the validation, the results of machining tests on a demonstrator blisk made of Inconel 718 are presented and discussed.
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PublicationMachinability analysis for milling of additively manufactured Inconel 718 with specifically induced porosity( 2022)Compared to conventional manufacturing technologies, additive manufacturing (AM) offers great design freedom, the integration of functions into components, new lightweight construction concepts and high material efficiency. This technology is increasingly coming into focus in aerospace and turbomachinery engineering, especially the Laser Powder Bed Fusion (LPBF) process. LPBF is already being used for some aerospace components that are often subject to high thermal and mechanical loads. Depending on the component geometry, support structures are required for additive manufacturing, which then have to be removed, usually by machining. Among others, the use of material with specifically induced porosity is suitable as a support structure. This ensures good heat dissipation and thus homogeneous component properties, high retention forces and short process times in the LPBF process. However, the machinability of porous, additively manufactured material has hardly been researched to date. This paper therefore presents the results of machinability investigations with porous, additively manufactured Inconel 718. The investigations included the analysis of active cutting force, cutting tool wear, surface finish and chip geometry in the milling process with tungsten carbide cutting tools. It was found that with the porous material, the dominant type of wear is early starting chipping of the cutting tool edges. The active force decreases with increasing porosity. Partial smearing of the pores was observed on the milled surfaces. The chips of the porous material show a disrupted surface. In future investigations, the aim is to improve the wear behaviour when milling porous Inconel 718.
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PublicationKnowledge-Based Process Design Optimisation in Blisk Manufacturing( 2022)The manufacturing process of blade-integrated disks (blisks) represents one of the most challenging tasks in turbomachinery manufacturing. The requirement is to machine complex, thin-walled blade geometries with high aspect ratios made of difficult-to-cut materials. In addition, extremely tight tolerances are required, since the smallest deviations can lead to a reduction in efficiency of the blisk in the later use. Nowadays, the ramp-up phase for the manufacturing of a new blisk is time and cost intensive. To find a suitable manufacturing process that meets the required tolerances of the blisk, many experimental tests with different process parameters and strategies are necessary. The used approach is often trial and error which offers limited testing opportunities, is time consuming and wastes resources. Therefore, the objective of this paper is to develop a knowledge-based process design optimization in blisk manufacturing. For this purpose, this paper picks up the results from our previous work. Based on these results, an experimental validation of the two process design tasks "number of blocks"and "block transition"is conducted. As part of the validation, the results of machining tests on a demonstrator blisk made of Inconel 718 are presented and discussed.
