advanced material removal technology (amrt) … · 2010. 6. 24. · outline •nrc iar-amtc...

animation/case14.pre

Outline

• NRC IAR-AMTC Profiles

• Areas of Common Interest in Machining: Modeling and simulation of the machining process.

Process optimization based on selection of machining strategy.

High performance superabrasive grinding technology,

Laser assisted machining of difficult-to-cut materials,

Sustainable Manufacturing; Near Dry Machining or Minimum

Quantity Lubrication (MQL),

Dynamics modeling for machining thin structures.

NRC-AEROSPACE MANUFACTURING

Institute for Aerospace

Research (IAR)

IAR PROFILE

The main centre for aerospace research in

Canada

• 350 employees (100 guest workers)

• $30-35M budget ($20M income)

• 2 Ottawa sites, 1 Montreal site

Five Laboratories

• Aerodynamics (AL)

• Structures & Materials

Performance (SMPL)

• Flight Research (FRL)

• Gas Turbine (GTL)

• Manufacturing (AMTC)


AMTC R&D Program Scope

Four Technology Thrusts :

• Material removal technologies.

• Forming and joining of metallic products.

• Automation, robotics and IMS.

• Forming and joining of composite products


1. Machining/ Drilling of Composites and MMC

1. Process Development and Optimization; VAM, orbital

drilling (S/A tools), and MQL technologies.

2. Defect characterization and effect of defects

(testing/modeling of mechanical performance).

3. Process modeling.

2. Grinding/Polishing Processes

1. HP/Superabrasive Grinding; processes development for

5X grinding.

2. Process modeling and simulation (virtual grinding).

3. Machinability Enhancement, SustainableManufacturing and Tool Life Management

1. Machinability of aerospace materials.

2. Laser assisted machining.

3. Minimum Quantity Lubrication (MQL).

FY

FZFX

NRC Material Removal R&TD Program


4. Physics-based Modeling / Simulation of the Machining System 1. Identification of materials constitutive laws in

machining; metals/ composites, MMC.

2. Dynamics of Tool-WP-Fixture System.

3. Simulation of the machining process; distortion,

residual stresses, burr formation.

5. Process Optimization and Control

1. Adaptive control / optimization of machining

processes for composite/metallic components.

2. Process monitoring for Closed Machining System.

3. Compensation of thermal errors in machine tools/

workpiece and CMM structures.

NRC Material Removal R&TD Program


-3

-2

-1

0

1

2

3

0 500 1000

Resid

ual e

rro

rs, m

m

Time, s

animation/case14.pre

• Develop a methodology for material

characterization at high (t, e, e, T)..

Physics-Based Modeling

and Simulation

Laser

Head

IR

Camera

Workpiece

Cutting

Tool

Dynamometer

Laser preheated cutting tests

Slip

Ring


Model Fc

(N/mm)

tc

(mm)

lc

(mm)

Proposed 10% 40% 20%

S-O-T-A 350% 200% 80%

• Process simulation and

optimization (residual

stresses, distortion, burr

formation, microstructure

evolution, …).


and Simulation


DFRM_Case14/case14.pre

Model Fc

(N/mm)

tc

(mm)

lc

(mm)

Proposed 10% 40% 20%

S-O-T-A 350% 200% 80%

• Process simulation and

optimization (residual

stresses, distortion, burr

formation, microstructure

evolution, …).

0.99

Martensite

Volume Fraction-Martensite0.99

0.66

0.33

0.00

MartensiteMartensite+

Ferrite

Ferrite +

Pearlite


and Simulation


DFRM_Case14/case14.pre

Evaluation of different strategies for pocket-milling of Beta-

Titanium Ti-10V-2Fe-3Al. The assessment was made base

on the following criteria:

• Cutting forces.

• Power consumption.

• Tool wear.

• Form accuracy.

• Dimensional accuracy.

• Surface finish.

• Machining Time.

Machining Strategies

Process Optimization based on Selection of Machining Strategy


Strategies and Cutting Conditions:

Three combinations of cutting operations including helical milling, drilling,

plunging, slotting, end and side milling.

Cutting Tools:Solid and indexable-insert endmills, drills, and plungers.

Tool diameters between 16 and 32 mm.

Cutting Speed:Up to 120 m/min (394 sfm).

Feed/Tooth:Up to 0.2 mm (0.008”)

Radial Immersion:Up to 32 mm (11/4” )

Depth of Cut:Up to 39.8 mm (1.567”)



Machining Strategies: Summary

Po

cket

Cu

tting

Tim

e

Pocket Quality

To

ol

Wear

Fin

ish

Ap

peara

nce

Fo

rm

Accu

rac

y

Dim

en

sio

nal

Accu

rac

y

Su

rface

Ro

ug

hn

ess

Recta

ng

ula

r

SII SIII SIII SIII SIII SI

SI SII SII SII

SI & SII

SII

SIII SI SI SI SIII

Tria

ng

ula

r

SI SIII SII SII SIII SI

SIII SII SII SIII SII SIII

SII SI SI SI SI SII

Rating: Best: Green 2nd Best: Blue Third: Red



Objective:

Modeling of high speed deep grinding

of steels, nodular C.I. AND Ni-alloys

Process optimization to achieve

maximum material removal rates.

Challenges:

Usage of high wheel speeds (up to

75,000 rpm).

Perform OD grinding on machining

centers with multiple functionality and

control systems.

Workpiece materials, e.g., superalloys,

and nodular cast iron which is very

sensitive to thermal damage and

cracking.

High Performance Superabrasive Grinding

Experimental setup

Workpiece

Wheel dresser

Sensor

AE sensor (uniformity

of dressing in axial)

Vibration

DynamicBalancer


Prediction of Grinding Force Distribution in the

Contact Zone

• For process Optimization: Prediction of temperature

distribution, thermal damage, surface finish, part

dimension, wheel life, surface integrity, cycle times etc.

• Analytical solution.

• Experimental; a novel technique.

• 3D-Numerical solution; multi grain case with random

grain height and spatial distributions. Horizontal Cutting Force

Time,s

0 10 20 30 40 50 60 70

Forc

e, N

-40

-30

-20

-10

0

10

20

Total Force

Coolant Force

Cutting Force

Vertical Cutting Force

Time,s

0 10 20 30 40 50 60 70

Fo

rce

, N

-40

-20

0

20

40

60

80

100

120

140

160

Total Force

Coolant Force

Cutting Force

CBN

High Performance Superabrasive Grinding


Laser Assisted Machining of Inconel 718

170

130

11095 90

140

7565 60 55

240

180165

160 160

0

50

100

150

200

250

300

Conventional 100

Laser - 100 Laser - 150 Laser - 200 Laser - 250

Fo

rce

(N

)

V, m/min

Cutting Forces

Feed Forces

Radial Forces

1.46

0.280.42

0.26

0.53

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1.60

1.80

2.00

100 Conv. 100 LAM 150 LAM 200 LAM 250 LAM

Ra

(μ

m)

V, m/min

Experimental setup

of Laser Assisted

Machining

Laser assisted Machining of Difficult-to-Cut Materials

Surface Smearing

63 μm

Smearing

Conventional

127 μm

LAM

SEM image of

failed ceramic tool

at 300 m/min and

0.4 mm/rev under

(a) conventional,

(b) LAM.

Adhesion

Rake Face Rake Face

Flank

FaceFlank

Face200 mm200 mm(a)

Abrasion

(b)


NEAR DRY MACHINING (NDM) /

MINUMUN QUANTITY LUBRICATION (MQL)

Motivation

Substitution of to dry and wet cutting due to

its impact on the economy (cost reduction

by 20-35 %) [CIRP, EU FP-5 Program] and the

environment (50% reduction of power

consumption and 60% reduction in waste

disposal volumes).

Description

Effect of MQL on machining performance in

turning, drilling and milling of Al 6061, 300M

high strength steel, and CFRP composites,

compared to dry and wet cutting.MQL Application Unit Setup

Calibrated oil

flow meter

Sustainable Manufacturing:Near Dry Machining/MQL


MQL Milling Applications Al 6061

IR camera

MQL nozzle

Cutter

Force

Transducer

MQL

Al adhesion

on the tool

Broken

edge

Dry, broken (4,000 rpm)Surface damage

Alumium adhering to the workpiece

0

100

200

300

400

0 5 10 15

Tem

pera

ture

(°C

)

Time (s)

MQL

Dry

Minimum Quantity Lubrication (MQL): (4,000 rpm, 0.15 mm/tooth, 5 mm depth of cut, 9 ml/hr)


Sustainable Manufacturing:Near Dry Machining/MQL

0

100

200

300

400

0 400 800 1200 1600

Length of cut, mm

Nose r

adiu

s w

ear,

mm

Dry

Flood

MQL

Turning Applications0

0.4

0.8

1.2

0 100 200 300Nose Radius Wear, mm

Roughne

ss R

a,

mm

Dry

Flood

MQL

M300 Steel (400 m/min)

Dry

Flood

MQL

Development of model for the dynamics of thin-walled structures:

The continuous change of thickness. Effect of the constraints imposed by the fixture. Prediction errors < 10%. Computationally efficiency: One order of

magnitude improvement. Numerically and experimentally validation.

Locator/

support

Edge

clamp

Custom clamp

WorkpieceSide 1

Side 2

Side 3

Side 4

Span 1Span 2

Span 3Span 4


Machining Dynamics of

Thin Structures

Development of a data-base for the stability lobes of tool/tool holder systems and application to the optimization of the milling process of complex parts.

Part Tool

Effect of Wp2 and US-FAM063-0028

dynamics in down milling rdoc =12.6 mm,

orientation = 0 Degrees

0

4

8

12

16

20

0 500 1000 1500 2000 2500(rpm)

ax

ial d

ep

th o

f c

ut

(mm

)

tool dynamics Wp2 dynamics

Wp2 and tool dynamics upper limit of doc

Machining Dynamics of

Thin Structures

Effect of tool length on stability lobes.

US-FAM063-0027 and -0028 tools, rdoc =12.6 mm,

orientation = 0 Degrees

0

2

4

6

8

0 500 1000 1500 2000 2500

(rpm)

ax

ial

de

pth

of

cu

t

(mm

)

Tool length 175 mm Tool length 265 mm

Uper limit of doc

US-FAM063-0028, rdoc=12.6 mm, D=63mm

0.5

1.0

1.5

2.0

2.5

500 1000 1500 2000(rpm)

ad

oc

(m

m)

0 Deg 30 Deg 60 Deg

90 Deg Enveloppe adoc-limit

Other Areas of

Common Interest

• Robotized welding processes

• Processes development for injection molding that offer equivalent

mechanical properties of compression molded plastic composites

(IMI)).

• Material development for injection molding reinforced by glass

fibre (IMI).

• Precision machining of large complex and large components; jet

engine components, fan frames, duct fan fronts, compressors

frames, etc.

• BTA deep hole drilling/ Gundrilling.

• Precision sheet metal processing.

• In-situ repair of machine tools spindles (inner surface taper

correction).


• Hydroforming.

• Remote laser welding systems.

• Friction stir welding.

• Robotized systems (HS vision platform).

• Hard coatings (CVD, PVD).

• Manufacturing sensors technology, for measurement and control

purposes.


Other Areas of

Common Interest

Thank you! Questions?

See also: NRCaerospace.com

advanced material removal technology (amrt) … · 2010. 6. 24. · outline •nrc iar-amtc...

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