Upload
others
View
1
Download
0
Embed Size (px)
Citation preview
IFT Institute for Production Engineering
and Laser Technology
Univ.Prof. DI Dr. techn. habil. Friedrich Bleicher
Results of the 3rd FiberCut BenchmarkD. Finkeldei, G. Wiesinger, F. Bleicher, F. Ott, H. Hager, P. Smuda, S. Bauer
Jahresabschluss 2018
Workshop zum 3. Benchmark
November 21st, 2018
IFT Institute for Production
Engineering and Laser Technologyslide 2
2 Measurement of tool geometry
outline
1 Benchmark conditions
3 Results
4 Summary and Outlook
IFT Institute for Production
Engineering and Laser Technologyslide 3
Tooling-Benchmark 2018
Benchmark 2018
Offer
■ per benched material and up to 5 shank tools (drills or mills)
■ machining experiments
■ metrological evaluation
■ includes the FRP workpiece materials
■ participation at the Fibercut-Workshop
IFT Institute for Production
Engineering and Laser Technologyslide 4
Tooling-Benchmark 2018
Willemin-Macodel SA W-418 CNC Technical specifications
description Macodel SA W-418 CNC
manufacturer Willemin
clamping system SK25
max. spindle speed 18,000 rpm
total power requirement 10 kW
machine weight 2,700 kg
longitudinal distance(x-axis) 500 mm
cross distance(y-axis) 250 mm
vertical distance(z-axis)
400 mm
construction year 1996
total number of axis 5
IFT Institute for Production
Engineering and Laser Technologyslide 5
Benchmark Conditions
Protective equipment & Force measurement
■ Assembling of the workpiece on a special
adapter plate
■ Extraction directly at workpiece & spindle
■ Cutting force and torque measurement via
3-axis dynamometer (Kistler 9129 AA)
Sensitivity: Fx ≈ -8,1; Fy ≈ -4; Fz ≈ -8,1 [pc/N]
Torque meas. range: Mx, My , Mz -500…500 [Nm]
Force meas. range: Fx, Fy, Fz -10…10 [kN]
Area of workpiece assembly: 90x105 [mm]
Kistler 9129AA
Overload emergency stop: Fx, Fy, Fz 20 [%]
IFT Institute for Production
Engineering and Laser Technologyslide 6
Benchmark Conditions
Tool selection and milling operation
1
2
3
45
6
7
8
1011
12
13
14
15
16
17
18
9
Milling operations:
■ Peripheral milling
■ 1: circumferential slot
■ 2: linear slot across
■ 3: linear slot along
■ 4: linear slot 30° angularly
■ 5: linear slot 45° angularly
■ 6: linear slot 60° angularly
■ 7: trimming across
■ 8: trimming along
■ 9: trimming 45° angularly
■ End milling
■ 10: circumferential slot
■ 11: linear slot across
■ 12: linear slot along
■ 13: linear slot 30° angularly
■ 14: linear slot 45° angularly
■ 15: linear slot 60° angularly
■ 16: trimming across
■ 17: trimming along
■ 18: trimming 45° angularly
Milling
CFRP 18
GFRP 8
IFT Institute for Production
Engineering and Laser Technologyslide 7
Experimental setup
Drilling operations:
■ 1: basic parameter
■ 2: variation parameter 1
■ 3: variation parameter 2
■ 4: variation parameter 3
■ 5: variation parameter 4
■ 6: variation parameter 5
■ 7: variation parameter 6
■ 8: variation parameter 7
■ 9: variation parameter 8
■ 10: variation parameter 9
■ 11: variation parameter 10
■ 12: variation parameter 11
Workpiece for drilling of CFRP / GFRP
Cutting speed
Fe
ed
pe
r to
oth
Basic parameter
Variation parameters
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
Drilling
CFRP 23
GFRP 7E. Paucksch, S. Holsten, M. Linß und F. Tikal, Zerspantechnik - Prozesse,
Werkzeuge, Technologien, Wiesbaden: Vieweg+Teubner Verlag, 2008.
IFT Institute for Production
Engineering and Laser Technologyslide 8
Determination of workpiece damage
1-dimensional maximum method (1-DMM)
Measurement of biggest damage at
the front and back of the workpiece
Fraying index
Delamination index
Splintering index
Quality index
𝑓𝑖 [%] =𝑓𝑚𝑎𝑥
𝐷∗ 100
𝑑𝑖 [%] =𝑑𝑚𝑎𝑥
𝐷∗ 100
𝑠𝑖 [%] =𝑠𝑚𝑎𝑥
𝐷∗ 100
𝑞𝑖 % =𝑓𝑖 + 𝑑𝑖 + 𝑠𝑖
3𝑞𝑖, 𝑡𝑜𝑡𝑎𝑙 % = 𝑞𝑖, 𝑓𝑟𝑜𝑛𝑡 + 𝑞𝑖, 𝑏𝑎𝑐𝑘
sm
ax
dmax
f ma
x
Fraying f
Delamination d
Splintering s
Source: R. Zemann, J. Sacherl, W. Hake, and F. Bleicher, “New measurement processes to define the
quality of machined fibre reinforced polymers,” Procedia Eng., vol. 100, no. January, pp. 636–645, 2015.
IFT Institute for Production
Engineering and Laser Technologyslide 9
Evaluation of the benchmark plates
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
1 2 3 4 5 6
7 8 9 10 11 12
Drilling operation
12
3
4
5
6
7
8910
11
12
13
14
1516
According to the occurrence of a type of damage in one of these sectors,
the largest characteristic (dimension) of this type of damage is detected.
This method is used for the direct assignment of the damage types
to positions on the bore wall or edge.
benchmark plate top:
benchmark plate bottom: mirrored approach
IFT Institute for Production
Engineering and Laser Technologyslide 10
Evaluation of the benchmark plates
1
2
3
45
6
7
8
1011
12
13
14
15
16
17
18
9
Milling operation
benchmark plate bottom: mirrored approach
1. Start of sector definition at the tool entry
2. Sector definition is done according to the
long-hole or circular groove scheme
(The scheme has to be superimposed over the geometry)
3. For circumferential slot: sector numbering along feed direction
4. For slot: sector numbering along feed direction;
Symmetry axis divides slot and subdivides
"the pickup positions into two sections" (eg 1.1 and 1.2)
benchmark plate top:
1
2
3
4
5
6
789
10
11
12
13
1415 16
1.1
2.1
3.14.1 5.1 6.1 7.1 8.1 9.1 10.1
11.1
12.1
13.1
13.2
12.2
11.24.2 5.2 6.2 7.2 8.2 9.2 10.2
3.2
2.2
1.2
IFT Institute for Production
Engineering and Laser Technologyslide 11
outline
1 Benchmark conditions
2 Measurement of tool geometry
3 Results
4 Summary and Outlook
IFT Institute for Production
Engineering and Laser Technologyslide 12
Tool measurement
Technical specifications
description Optical 3D surface measuring device
manufacturer Alicona Imaging GmbH
measuring principle Focus-Variation
measuring system Optical, non-contact 3-dimensional measuring
max. verticalresolution 10 nm (100x objective)
max. laterale resolution 0,44 µm (100x objective)
min. measurableradius 1 µm (100x objective)
objective revolver 5 objective (5x/10x/20x/50x/100x)
measuring rangeX/Y/Z 100/100/100 mm
measuring volume 1 dm³
max. sample mass 20 kg
sample surface Surface topography Ra over 10 nm,solid surface
Technical details• IF-Real3DRotationUnit for the complete
detection of components• Digitally controllable LED ring light
alicona.com
IFT Institute for Production
Engineering and Laser Technologyslide 13
Tool measurement - milling
axial
radial
cutting edge 1 (CE1) cutting edge 2 (CE2)
flank face
rake face
flank face
rake face
flank face
rake face
flank face
rake face
cutting edge radius:
rβ = 13,06 ±0,20 µm
wedge angle:
β = 74,46 ±0,05°profile flattening:
Δr = 08,71 ±0,19 µm
cutting edge radius:
rβ = 13,19 ±0,35 µm
wedge angle:
β = 68,67 ±0,67°profile flattening:
Δr = 10,86 ±0,15 µm
CE2 - axial
CE2 - radial
CE1 - axial
CE1 - radial
Δr
Sγ Sα
cutting
wedge
IFT Institute for Production
Engineering and Laser Technologyslide 14
Δr
Sγ Sα
cutting
wedge
Tool measurement - drilling
cutting edge 1 (CE1) cutting edge 2 (CE2)
flank face
rake face
flank face
rake face
cutting edge radius:
rβ = 03,40 ±0,65 µm
wedge angle:
β = 44,83 ±0,10°profile flattening:
Δr = 05,43±1,19 µm
ax
ial
CE1 - axial
IFT Institute for Production
Engineering and Laser Technologyslide 15
Measurement of tool geometry
0
5
10
15
20
25
30
drilling milling
axial axial radial
cu
ttin
ge
dg
era
diu
sr β µm
number of cutting edges (CE)
shank drills end mills
no. of. CE 2 4 4 6 8 9
no. of tools* 34
(89,5%)
4
(10,5%)
9
(36%)
3
(12%)
9
(36%)
4
(16%)
tool-Ø no.
shank
drills 4,85 mm 2 5%
6,00 mm 16 42%
6,35 mm 20 53%
en
d m
ills 6,00 mm 8 32%
8,00 mm 3 12%
10,0 mm 14 56%
selected example geometries
CFRP
GFRP
*number of tools including experimental used and reserve cutting tools
IFT Institute for Production
Engineering and Laser Technologyslide 16
2 Measurement of tool geometry
outline
1 Benchmark conditions
4 Summary and Outlook
3 Results
IFT Institute for Production
Engineering and Laser Technologyslide 17
CFRP milling resultsQ
ua
lity
Ind
ex
QI
0,0%
0,5%
1,0%
1,5%
2,0%
2,5%
3,0%
3,5%
WK
Z5
5
WK
Z2
6
WK
Z6
2
WK
Z6
9
WK
Z0
3
WK
Z4
6
WK
Z5
1
WK
Z9
3
WK
Z4
9
WK
Z0
5
WK
Z8
8
WK
Z5
8
WK
Z3
0
WK
Z7
7
WK
Z7
0
WK
Z5
8
WK
Z2
3
WK
Z2
4
IFT Institute for Production
Engineering and Laser Technologyslide 18
CFRP drilling results
0,0%
0,5%
1,0%
1,5%
2,0%
2,5%
3,0%
3,5%
WK
Z5
0
WK
Z8
2
WK
Z4
8
WK
Z7
8
WK
Z6
3
WK
Z8
7
WK
Z1
8
WK
Z5
7
WK
Z5
9
WK
Z8
0
WK
Z1
6
WK
Z5
4
WK
Z4
0
WK
Z3
8
WK
Z4
3
WK
Z5
6
WK
Z3
7
WK
Z7
5
WK
Z7
1
WK
Z4
1
WK
Z3
4
WK
Z2
2
WK
Z0
7
Qu
ali
tyIn
de
x Q
I
IFT Institute for Production
Engineering and Laser Technologyslide 19
CFRP drilling results
0
10
20
30
40
50
60
70
80
90
WKZ50 WKZ82 WKZ22 WKZ07
Fe
ed
fo
rce
Ff
WKZ50feed force over tool rotation
tool rotation
WKZ82
tool rotation
WKZ22
tool rotation
WKZ07
tool rotation
WKZ50feed force over tool rotation
tool rotation
N
IFT Institute for Production
Engineering and Laser Technologyslide 20
GFRP milling results
0,0%
1,0%
2,0%
3,0%
4,0%
5,0%
6,0%
7,0%
8,0%
9,0%
10,0%
WK
Z9
0
WK
Z3
6
WK
Z8
3
WK
Z8
6
WK
Z1
3
WK
Z1
2
WK
Z6
7
WK
Z6
6
Qu
ali
tyIn
de
x Q
I
IFT Institute for Production
Engineering and Laser Technologyslide 21
GFRP drilling results
0,0%
1,0%
2,0%
3,0%
4,0%
5,0%
6,0%
7,0%
8,0%
9,0%
10,0%
WK
Z4
2
WK
Z0
2
WK
Z2
7
WK
Z2
8
WK
Z6
5
WK
Z8
9
WK
Z4
4
Qu
ali
tyIn
de
x Q
I
IFT Institute for Production
Engineering and Laser Technologyslide 22
GFRP drilling results
-10
0
10
20
30
40
50
60
70
WKZ42 WKZ02 WKZ89 WKZ44
Fe
ed
fo
rce
Ff
WKZ42feed force over tool rotation
tool rotation
WKZ02
tool rotation
WKZ89
tool rotation
WKZ44
tool rotation
N
IFT Institute for Production
Engineering and Laser Technologyslide 23
2 Measurement of tool geometry
outline
1 Benchmark conditions
3 Results
4 Summary and Outlook
IFT Institute for Production
Engineering and Laser Technologyslide 24
0 0,04 0,08 0,12 0,16 0,2
0 100 200 300 400
Summary
Cutting parameters inside the benchmarks
Benchmark 2015: 13 twist drills ⋅ 2 peripheral milling cutters ⋅ 41 end mills
Benchmark 2018: 30 twist drills ⋅ 1 peripheral milling cutters ⋅ 25 end mills
drilling
milling
drilling
milling
CF
RP
GF
RP
Cutting speed vc
m/min
Feed per tooth fzmm/z
2015
0 100 200 300 400
0 0,04 0,08 0,12 0,16 0,2
m/min
mm/z
2018
drilling
milling
drilling
milling
CF
RP
GF
RP
IFT Institute for Production
Engineering and Laser Technologyslide 25
0%
5%
10%
15%
20%
25%
30%
35%
Bohre
n
Frä
sen
Besäum
en
Bohre
n
Frä
sen
Besäum
en
Summary
Benchmark 2018
CFRP GFRP
Benchmark 2013
Benchmark 2015
Benchmark 2018
drilli
ng
drilli
ng
slo
tm
illin
g
slo
tm
illin
g
trim
min
g
trim
min
g
Qu
ali
tyIn
de
x Q
I
IFT Institute for Production
Engineering and Laser Technologyslide 26
Outlook
Continuing of the tooling benchmark with
aerospace certificated materials
(CFRP or multilayer CFRP-(Ti/Al) stacks)
Continuing of the tooling benchmark with
conventional GFRP and AFRP materials
Maybe, transition into tool life experiments
Laser acoustic investigation and monitoring of the
cutting process
Tooling Benchmark 2019
FiberCut III16 CFRP parts
4 different technologies
CFRP Wet
Compression Molding
CFRP Resin Transfer
Molding
CFRP-Steel hybrid
CF Sheet Molding
Compound
https://www.compositesworld.com/articles/is-the-bmw-7-series-the-future-of-autocomposites
Development of a
simulation model
for the machining of FRP
Cu
ttin
ge
xp
erim
en
ts
with
CF
RP,
GF
RP,A
FR
P
an
dC
FR
P-T
ita
niu
m
Me
tro
log
ica
l in
ve
stig
atio
n
of
the
wo
rkp
iece
an
dto
ol
fun
da
me
nta
l in
ve
stig
atio
n
ort
ho
go
na
l cu
ttin
g
Assembly of the task force FiberCut
as a discussion platform for innovative challenges
in the field of the machinability of fiber reinforced plastics.
IFT Institute for Production Engineering
and Laser Technology
Univ.Prof. DI Dr. techn. habil. Friedrich Bleicher
Institute for Production Engineering
and Laser Technology
Getreidemarkt 9/BA/8 OG
1060 Wien
T +43 1 58801 31101
Contact person
CONTACT
Daniel Finkeldei, M.Sc.
Franz-Grill-Straße 4/Obj. 221/E311-1
A-1030 Vienna
T +43 1 58801 31112