Papers by Keyword: Lightweight Components

Abstract: Lightweight frame components made of aluminum and load optimized connecting elements allow the reduction of weight and energy consumption as well as the increase of payload. Complex frame structures which nowadays can be designed and optimized with the help of modern simulation technologies require the use of adapted manufacturing technologies. Especially the flexible machining of single or limited products on the basis of common machining strategies is still inefficient and economically unacceptable. This article describes the development of adequate strategies for a high quality machining using simultaneous five-axis milling. Consequently, the machining of composite extruded aluminum profiles with continuously embedded steel-wire elements and the preparation of joining areas on nodes and commonly extruded profiles for innovative joining by forming processes have been analyzed.

Abstract: Innovative composite extrusions consisting of an aluminium matrix material with steel fibres for reinforced lightweight constructions require adapted cutting technologies. Due to the resulting tool wear when machining such composite materials, new tools and processes have to be developed. The following article describes experimental investigations concerning conventional drilling operations in comparison to helix milling operations for the manufacturing of holes in these materials. Therefore especially wear and quality aspects are discussed. Furthermore a flexible cutting process for thin walled lightweight frame connector elements to combine profiles is described. To obtain detailed process knowledge also FEA-Simulations of the thermo-mechanical loads affecting the workpiece during the process are performed.