Papers by Author: Eduard Ungemach

Abstract: In most cases the simulation of temperature distributions in machined workpieces is carried out by moving a heat source along a predefined workpiece model within a commercial FEM-system. For performance reasons, the material removal is often neglected or performed by removing small predefined parts of the workpiece. Furthermore, the heat source often has a constant heat flux and therefore it is not dependent on the current tool engagement. In this paper we present a voxel-based finite difference method for the thermal behavior of the process-state dependent workpiece, which is integrated into the milling simulation system NCChip, developed at the ISF. This simulation is capable of modeling the cutting forces along any arbitrary NC-path. Since the tool rotation and the cutting edges in this time domain simulation are divided into discrete angle steps and cutting wedges respectively, the thermal energy that is applied to the workpiece at each time step and at each cutting wedge can be computed as a fraction of the corresponding cutting work. In this way, the correct heat is introduced to the workpiece exactly at the current contact zone of the tool.

Abstract: Lightweight extrusion profiles with reinforcement elements are promising news in the domain of lightweight construction. The machining of them suffers from several problems: Aside from the question of choosing a suitable tool, feed rate, and milling strategy, an excessive rise in temperature could lead to stress and even a distortion due to the differing thermal expansion of the reinforcement material and the surrounding matrix material. A simulation of the milling process could, in addition to force and collision calculations, recognize this case before manufacturing. For certain milling applications like seal surfaces, a certain roughness of the manufactured surface is necessary. In many other cases, a smooth surface of very high quality is desirable. Available simulation systems usually completely lack the simulation of dynamic effects, which have a great effect on the final surface quality, and therefore are not able to predict the resulting surface quality. In this paper simulation methods are presented that are capable of simulating the dynamic behavior of the tool in the milling process and the resulting flank and ground surface structures. Additionally, a fast temperature simulation for heterogeneous workpieces with reinforcement elements, which is based on the finite difference method and cellular automata, is introduced.

Abstract: Lightweight structures are an important element in today’s production industry. For the multi-axis milling of these structures some aspects have to be considered to achieve a good surface quality and to prevent damaging the milling machine during the machining process. In this article methods to determine suitable feed rates for the milling process, to identify parts of the workpiece with too much heat build-up, and to avoid collisions between workpiece and machine parts are presented. For this purpose a milling simulation based on a multi-dexel field workpiece model has been developed, in which two types of feed rate adaptation have been integrated. Work on a built-in temperature development simulation and collision control is in progress.