Project B4: Applying similarity mechanics and finite element simulations to increase process efficiency in soft and hard processing

Person in Charge: Dipl.-Ing. Julius Osterried

Motivation and aim:
The condition of highly stressed, notch containing components is changed within a process chain by sequential cutting processes, thus affecting performance and durability. The influence and interactions of sequential cuts on the final component condition are either not identified in detail or hard to determine. There is insufficient knowledge about residual stress development for machining processes with multi edged tools. The aim of the project is to simulate broaching as a sub process of a process chain while considering sequential cutting and to examine the influences of relevant process parameters. A prediction of the final component condition after machining, in dependency of the initial component condition is also developed.

Research	Results
FE modeling of sequential machining processes in 2D, transfer component conditions, linking to adjacent sub processes Determination of the surface layer condition with small element edge sizes and remeshing for realization of material separation Numerical study of the influences of process parameters and initial conditions of the component Development of a forecasting model to describe the component condition after chip removal process done by broaching	Residual stress state depends on process parameters as well as on the number of sequential cuts With increasing number of cuts: change of surface residual stresses, as well as deeper tensile residual stresses for simultaneously decreasing cutting velocity and increasing uncut chip thickness Development of a steady state in the surface layer after a higher number of sequential cuts