Vibration reduction during turning and milling of high-performance materials with tool holders produced by selective laser melting

• Applicant: Professor Dr.-Ing. Dirk Biermann
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2016
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 315697914

At the beginning of the project, the main goal is to achieve validated knowledge on the dissipation mechanisms acting in particle-damped tool holders. This well-founded extended expertise will be directly used in the following to perform an analytically targeted and simulation-based optimisation of the particle damper concepts successfully developed in the previous project with the aim of increasing process stability when turning and milling TiAl6V4 and bainitic steel (23MnCrSiMoS6). At the project‘s beginning, a special analogy test setup is used to fundamentally analyse which specific influence on the dissipation processes acting in particle-filled indexable insert holders (WSPH) can be attributed to a particular constructive modification step. Equally, the extent to which particle size, bulk density and surface topography of the applied filling material, as well as the viscosity of the ambient medium, affect the system damping capacity will be investigated without any machining-specific influences. Based on these results, the application behaviour of the most dissipation-efficient WSPH concepts in turning will first be fundamentally analysed in the project's further course. On the one hand, a direct comparison of the WSPH damping during turning with the dissipation behaviour during the analogy tests allows a well-founded evaluation of the extent to which an analogy- and simulation-based system design is possible. Due to this, the basic knowledge for the design of particle-damped systems can be extended, regardless the specific machining operation. On the other hand, after further WPSH improvements have been carried out in accordance with the initial machining tests, detailed application analyses can be carried out for targeted, filling medium-based system adjustment under additional consideration of the tool wear and the surface quality. Finally, the most damping-suitable particle damper (PD) developed in the first project parts are to be used directly for the simulation-based further development of the particle-damped HSK63 tool holders, taking into account experiences from the previous project. In order to carry out basic system analyses during milling as time- and cost-efficiently as possible, additively manufactured damping elements which can be integrated into modified, conventionally produced HSK63 tool holders will be focused on initially. The extent to which the rotational loading influences the dissipation performance of the PD, which were primarily developed based on translational excitation, is a fundamental issue to be evaluated among others. These conclusions, which are also to be classified as superordinated project results, will also be used for the conceptual optimisation of HSK63 tool holders to be produced completely generatively. Similar to the final turning investigations, these tool holders are used for comprehensive application analyses, considering the most dissipation-efficient filling materials.

• DFG Programme: Research Grants