Module 3: Cutting conditions
By a systematic process layout parameters and novel tool concepts with damping characteristics will be determined. Micro simulation of the multi blade contact conditions of the milling process by using robust CAM-applications is an opportunity to improve the milling process (Figure 8: right). Process parameters and tool designs can be investigated regarding dynamic excitation and damping capabilities over the free form surface. One issue is the determination of a systematically optimized machining strategy for achieving homogenized cutting conditions to provide uniform cutting and engagement conditions as constant as possible while milling hard-to-machine materials so that there is a minimal variation of process forces (Figure 8: left, inhomogenized cutting conditions).
Contents of cutting conditions module (left: unequal cutting conditions, right: tool with enhanced damping and low excitation) (Figure 8)
Another issue is an unique test bench at Fraunhofer IPT for performing milling tests in analogy, which enables to discretely analyze the influence of the process input parameters on the thermo-mechanical load spectrum. Based on that, concrete conclusions can be made in terms of the real milling process and particularly questions concerning the tool, material and process parameter design can be clarified. This will contribute to a drastically enhanced process capability in terms of avoiding dynamic excitation and achieving superior damping capabilities.
Objectives of module 3