Title: Experimental and simulative investigations on machining aluminium lightweight structures

Authors: Dirk Biermann, Timo Engbert, Sven Grunert, Niels Hammer

Addresses: Institute of Machining Technology, Technische Universitat Dortmund, Baroper Strasse 301, Dortmund 44227, Germany. ' Institute of Machining Technology, Technische Universitat Dortmund, Baroper Strasse 301, Dortmund 44227, Germany. ' Institute of Machining Technology, Technische Universitat Dortmund, Baroper Strasse 301, Dortmund 44227, Germany. ' Institute of Machining Technology, Technische Universitat Dortmund, Baroper Strasse 301, Dortmund 44227, Germany

Abstract: In industrial practice, the machining of lightweight profiles is associated with different problems. During conventional machining operations, process stability is often affected by material-dependent adhesion at the cutting edges. Due to adhesion, the quality of surfaces and bore-holes as well as the reliability of the machining operation often become inadequate. The accurate machining of thin-walled profiles is exceptionally difficult due to their elastic structure and their tendency to oscillate in the frame structure. During the machining of extruded steel wire reinforced light-metal-matrix profiles, tool wear is an additional crucial factor. The potential and limitations of process design for high quality bore-holes produced by drilling and circular milling of conventional and steel-wire reinforced aluminium profiles are presented in this paper. Both, experimental research and simulation-based analyses form the basis of this paper.

Keywords: aluminium machining; composites; lightweight construction; drilling; circular milling; orbital milling; simulation; FEA; finite element analysis; lightweight structures; extruded steel wire; tool wear.

DOI: 10.1504/IJMMM.2008.023718

International Journal of Machining and Machinability of Materials, 2008 Vol.4 No.4, pp.345 - 360

Published online: 08 Mar 2009 *

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