Workpiece Shape Deviations in Face Milling of Hybrid Structures

Abstract:

A currently common method to design high-performance workpieces is to combine two or more materials to one compound. This way, workpieces can be composed of the most qualified materials according to local loads.When machining high-performance workpiece compounds (e.g. cylinder crankcases), high quality requirements concerning the accuracy of dimension and shape as well as the surface roughness must be fulfilled. However, machining of workpiece compounds leads to unfavorable changes of the workpiece quality in comparison to machining of the single materials. Significant shape deviations occur when different materials are machined alternately in one cutting operation. This is due to unequal material properties, cutting characteristics, chip formation mechanisms as well as characteristic interactions between the single components.The focus of this research is on the process understanding as well as on the identification of measurable shape deviation indicators that describe the surface finish of hybrid structures. Here, the indicators material height deviation, transition deviation at the material joint, surface roughness deviation as well as surface defects (e.g. scratches) on the surface are presented. The overall aim of this research is to predict the surface finish resulting from face milling an aluminum/cast iron compound or a polyurethane/cast iron compound.

• Periodical: Materials Science Forum (Volumes 825-826)
• Pages: 336-343
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.825-826.336
• Online since: July 2015
• Authors: Berend Denkena, Thilo Grove, Eike Hasselberg*
• Keywords: Milling, Surface Analysis, Workpiece Compound

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