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Zerspankraftmodellierung und Prozessgrenzen der Umrissbearbeitung von FKV-Bauteilen mit scheibenförmigen Werkzeugen
Citation Link: https://doi.org/10.15480/882.14285
Publikationstyp
Doctoral Thesis
Date Issued
2025
Sprache
German
Author(s)
Advisor
Referee
Title Granting Institution
Technische Universität Hamburg
Place of Title Granting Institution
Hamburg
Examination Date
2024-12-11
Institute
TORE-DOI
First published in
Number in series
57
Citation
Technische Universität Hamburg (2025)
Machining of defined part contours is an essential step in the production of fiber-reinforced plastic (FRP) shell components. Besides milling, processes with disk-shaped tools such as abrasive cutting and sawing can be used for this purpose. In addition, Curved Circular Cutting (CCC) is a novel technology that enables the machining of curved contours with these type of tools. To date, however, there has been comparatively little research into these FRP machining processes. This results in a lack of suitable simulation models and detailed knowledge of the relevant technological process limits with regard to process design and optimization.
This thesis addresses this need and provides a mechanistic cutting force model that can be used for cutting force simulations with arbitrary disk-shaped tool geometries. This model includes for the first time oblique cutting with spatial cutting phenomena at the fibers of the FRP, which can occur in the contact zone due to complex engagement conditions, especially when using the CCC technology. The resulting effect on the cutting behavior of the orthotropic material is systematically investigated by machining tests on unidirectional CFRP, mathematically modeled and integrated into the cutting force model. In addition, the results of comprehensive experimental investigations are used to identify the technological process limitations of CCC and to derive recommendations for the application.
This thesis addresses this need and provides a mechanistic cutting force model that can be used for cutting force simulations with arbitrary disk-shaped tool geometries. This model includes for the first time oblique cutting with spatial cutting phenomena at the fibers of the FRP, which can occur in the contact zone due to complex engagement conditions, especially when using the CCC technology. The resulting effect on the cutting behavior of the orthotropic material is systematically investigated by machining tests on unidirectional CFRP, mathematically modeled and integrated into the cutting force model. In addition, the results of comprehensive experimental investigations are used to identify the technological process limitations of CCC and to derive recommendations for the application.
Subjects
Zerspankraft
Simulation
Faser-Kunststoff-Verbund
Räumliche Eingriffsbedingung
Trennschleifscheibe
Kreissäge
DDC Class
670: Manufacturing
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Name
Koettner_2025_Zerspankraftmodellierung-und-Prozessgrenzen.pdf
Size
9.19 MB
Format
Adobe PDF