Jahresabschluss 2018 Workshop zum 3. Benchmark Results of … · 2019-06-24 · 2 Measurement of...

IFT Institute for Production Engineering

and Laser Technology

Univ.Prof. DI Dr. techn. habil. Friedrich Bleicher

Results of the 3rd FiberCut BenchmarkD. Finkeldei, G. Wiesinger, F. Bleicher, F. Ott, H. Hager, P. Smuda, S. Bauer

Jahresabschluss 2018

Workshop zum 3. Benchmark

November 21st, 2018

IFT Institute for Production

Engineering and Laser Technologyslide 2

2 Measurement of tool geometry

outline

1 Benchmark conditions

3 Results

4 Summary and Outlook



Tooling-Benchmark 2018

Benchmark 2018

Offer

■ per benched material and up to 5 shank tools (drills or mills)

■ machining experiments

■ metrological evaluation

■ includes the FRP workpiece materials

■ participation at the Fibercut-Workshop



Tooling-Benchmark 2018

Willemin-Macodel SA W-418 CNC Technical specifications

description Macodel SA W-418 CNC

manufacturer Willemin

clamping system SK25

max. spindle speed 18,000 rpm

total power requirement 10 kW

machine weight 2,700 kg

longitudinal distance(x-axis) 500 mm

cross distance(y-axis) 250 mm

vertical distance(z-axis)

400 mm

construction year 1996

total number of axis 5



Benchmark Conditions

Protective equipment & Force measurement

■ Assembling of the workpiece on a special

adapter plate

■ Extraction directly at workpiece & spindle

■ Cutting force and torque measurement via

3-axis dynamometer (Kistler 9129 AA)

Sensitivity: Fx ≈ -8,1; Fy ≈ -4; Fz ≈ -8,1 [pc/N]

Torque meas. range: Mx, My , Mz -500…500 [Nm]

Force meas. range: Fx, Fy, Fz -10…10 [kN]

Area of workpiece assembly: 90x105 [mm]

Kistler 9129AA

Overload emergency stop: Fx, Fy, Fz 20 [%]



Benchmark Conditions

Tool selection and milling operation

1

2

3

45

6

7

8

1011

12

13

14

15

16

17

18

9

Milling operations:

■ Peripheral milling

■ 1: circumferential slot

■ 2: linear slot across

■ 3: linear slot along

■ 4: linear slot 30° angularly



■ 7: trimming across

■ 8: trimming along

■ 9: trimming 45° angularly

■ End milling

■ 10: circumferential slot

■ 11: linear slot across

■ 12: linear slot along




■ 16: trimming across

■ 17: trimming along

■ 18: trimming 45° angularly

Milling

CFRP 18

GFRP 8



Experimental setup

Drilling operations:

■ 1: basic parameter

■ 2: variation parameter 1











Workpiece for drilling of CFRP / GFRP

Cutting speed

Fe

ed

pe

r to

oth

Basic parameter

Variation parameters

1 2 3 4 5 6

7 8 9 10 11 12

1 2 3 4 5 6

7 8 9 10 11 12

1 2 3 4 5 6

7 8 9 10 11 12

Drilling

CFRP 23

GFRP 7E. Paucksch, S. Holsten, M. Linß und F. Tikal, Zerspantechnik - Prozesse,

Werkzeuge, Technologien, Wiesbaden: Vieweg+Teubner Verlag, 2008.



Determination of workpiece damage

1-dimensional maximum method (1-DMM)

Measurement of biggest damage at

the front and back of the workpiece

Fraying index

Delamination index

Splintering index

Quality index

𝑓𝑖 [%] =𝑓𝑚𝑎𝑥

𝐷∗ 100

𝑑𝑖 [%] =𝑑𝑚𝑎𝑥

𝐷∗ 100

𝑠𝑖 [%] =𝑠𝑚𝑎𝑥

𝐷∗ 100

𝑞𝑖 % =𝑓𝑖 + 𝑑𝑖 + 𝑠𝑖

3𝑞𝑖, 𝑡𝑜𝑡𝑎𝑙 % = 𝑞𝑖, 𝑓𝑟𝑜𝑛𝑡 + 𝑞𝑖, 𝑏𝑎𝑐𝑘

sm

ax

dmax

f ma

x

Fraying f

Delamination d

Splintering s

Source: R. Zemann, J. Sacherl, W. Hake, and F. Bleicher, “New measurement processes to define the

quality of machined fibre reinforced polymers,” Procedia Eng., vol. 100, no. January, pp. 636–645, 2015.



Evaluation of the benchmark plates

1 2 3 4 5 6

7 8 9 10 11 12

1 2 3 4 5 6

7 8 9 10 11 12

1 2 3 4 5 6

7 8 9 10 11 12

Drilling operation

12

3

4

5

6

7

8910

11

12

13

14

1516

According to the occurrence of a type of damage in one of these sectors,

the largest characteristic (dimension) of this type of damage is detected.

This method is used for the direct assignment of the damage types

to positions on the bore wall or edge.

benchmark plate top:

benchmark plate bottom: mirrored approach



Evaluation of the benchmark plates

1

2

3

45

6

7

8

1011

12

13

14

15

16

17

18

9

Milling operation

benchmark plate bottom: mirrored approach

1. Start of sector definition at the tool entry

2. Sector definition is done according to the

long-hole or circular groove scheme

(The scheme has to be superimposed over the geometry)

3. For circumferential slot: sector numbering along feed direction

4. For slot: sector numbering along feed direction;

Symmetry axis divides slot and subdivides

"the pickup positions into two sections" (eg 1.1 and 1.2)

benchmark plate top:

1

2

3

4

5

6

789

10

11

12

13

1415 16

1.1

2.1

3.14.1 5.1 6.1 7.1 8.1 9.1 10.1

11.1

12.1

13.1

13.2

12.2

11.24.2 5.2 6.2 7.2 8.2 9.2 10.2

3.2

2.2

1.2



outline



3 Results




Tool measurement

Technical specifications

description Optical 3D surface measuring device

manufacturer Alicona Imaging GmbH

measuring principle Focus-Variation

measuring system Optical, non-contact 3-dimensional measuring

max. verticalresolution 10 nm (100x objective)

max. laterale resolution 0,44 µm (100x objective)

min. measurableradius 1 µm (100x objective)

objective revolver 5 objective (5x/10x/20x/50x/100x)

measuring rangeX/Y/Z 100/100/100 mm

measuring volume 1 dm³

max. sample mass 20 kg

sample surface Surface topography Ra over 10 nm,solid surface

Technical details• IF-Real3DRotationUnit for the complete

detection of components• Digitally controllable LED ring light

alicona.com



Tool measurement - milling

axial

radial

cutting edge 1 (CE1) cutting edge 2 (CE2)

flank face

rake face

flank face

rake face

flank face

rake face

flank face

rake face

cutting edge radius:

rβ = 13,06 ±0,20 µm

wedge angle:

β = 74,46 ±0,05°profile flattening:

Δr = 08,71 ±0,19 µm


rβ = 13,19 ±0,35 µm

wedge angle:


Δr = 10,86 ±0,15 µm

CE2 - axial

CE2 - radial

CE1 - axial

CE1 - radial

Δr

Sγ Sα

cutting

wedge



Δr

Sγ Sα

cutting

wedge

Tool measurement - drilling

cutting edge 1 (CE1) cutting edge 2 (CE2)

flank face

rake face

flank face

rake face


rβ = 03,40 ±0,65 µm

wedge angle:


Δr = 05,43±1,19 µm

ax

ial

CE1 - axial



Measurement of tool geometry

0

5

10

15

20

25

30

drilling milling

axial axial radial

cu

ttin

ge

dg

era

diu

sr β µm

number of cutting edges (CE)

shank drills end mills

no. of. CE 2 4 4 6 8 9

no. of tools* 34

(89,5%)

4

(10,5%)

9

(36%)

3

(12%)

9

(36%)

4

(16%)

tool-Ø no.

shank

drills 4,85 mm 2 5%

6,00 mm 16 42%

6,35 mm 20 53%

en

d m

ills 6,00 mm 8 32%

8,00 mm 3 12%

10,0 mm 14 56%

selected example geometries

CFRP

GFRP

*number of tools including experimental used and reserve cutting tools




outline



3 Results



CFRP milling resultsQ

ua

lity

Ind

ex

QI

0,0%

0,5%

1,0%

1,5%

2,0%

2,5%

3,0%

3,5%

WK

Z5

5

WK

Z2

6

WK

Z6

2

WK

Z6

9

WK

Z0

3

WK

Z4

6

WK

Z5

1

WK

Z9

3

WK

Z4

9

WK

Z0

5

WK

Z8

8

WK

Z5

8

WK

Z3

0

WK

Z7

7

WK

Z7

0

WK

Z5

8

WK

Z2

3

WK

Z2

4



CFRP drilling results

0,0%

0,5%

1,0%

1,5%

2,0%

2,5%

3,0%

3,5%

WK

Z5

0

WK

Z8

2

WK

Z4

8

WK

Z7

8

WK

Z6

3

WK

Z8

7

WK

Z1

8

WK

Z5

7

WK

Z5

9

WK

Z8

0

WK

Z1

6

WK

Z5

4

WK

Z4

0

WK

Z3

8

WK

Z4

3

WK

Z5

6

WK

Z3

7

WK

Z7

5

WK

Z7

1

WK

Z4

1

WK

Z3

4

WK

Z2

2

WK

Z0

7

Qu

ali

tyIn

de

x Q

I



CFRP drilling results

0

10

20

30

40

50

60

70

80

90

WKZ50 WKZ82 WKZ22 WKZ07

Fe

ed

fo

rce

Ff

WKZ50feed force over tool rotation

tool rotation

WKZ82

tool rotation

WKZ22

tool rotation

WKZ07

tool rotation


tool rotation

N



GFRP milling results

0,0%

1,0%

2,0%

3,0%

4,0%

5,0%

6,0%

7,0%

8,0%

9,0%

10,0%

WK

Z9

0

WK

Z3

6

WK

Z8

3

WK

Z8

6

WK

Z1

3

WK

Z1

2

WK

Z6

7

WK

Z6

6

Qu

ali

tyIn

de

x Q

I



GFRP drilling results

0,0%

1,0%

2,0%

3,0%

4,0%

5,0%

6,0%

7,0%

8,0%

9,0%

10,0%

WK

Z4

2

WK

Z0

2

WK

Z2

7

WK

Z2

8

WK

Z6

5

WK

Z8

9

WK

Z4

4

Qu

ali

tyIn

de

x Q

I



GFRP drilling results

-10

0

10

20

30

40

50

60

70

WKZ42 WKZ02 WKZ89 WKZ44

Fe

ed

fo

rce

Ff


tool rotation

WKZ02

tool rotation

WKZ89

tool rotation

WKZ44

tool rotation

N




outline


3 Results




0 0,04 0,08 0,12 0,16 0,2

0 100 200 300 400

Summary

Cutting parameters inside the benchmarks

Benchmark 2015: 13 twist drills ⋅ 2 peripheral milling cutters ⋅ 41 end mills

Benchmark 2018: 30 twist drills ⋅ 1 peripheral milling cutters ⋅ 25 end mills

drilling

milling

drilling

milling

CF

RP

GF

RP

Cutting speed vc

m/min

Feed per tooth fzmm/z

2015

0 100 200 300 400

0 0,04 0,08 0,12 0,16 0,2

m/min

mm/z

2018

drilling

milling

drilling

milling

CF

RP

GF

RP



0%

5%

10%

15%

20%

25%

30%

35%

Bohre

n

Frä

sen

Besäum

en

Bohre

n

Frä

sen

Besäum

en

Summary

Benchmark 2018

CFRP GFRP

Benchmark 2013

Benchmark 2015

Benchmark 2018

drilli

ng

drilli

ng

slo

tm

illin

g

slo

tm

illin

g

trim

min

g

trim

min

g

Qu

ali

tyIn

de

x Q

I



Outlook

Continuing of the tooling benchmark with

aerospace certificated materials

(CFRP or multilayer CFRP-(Ti/Al) stacks)

Continuing of the tooling benchmark with

conventional GFRP and AFRP materials

Maybe, transition into tool life experiments

Laser acoustic investigation and monitoring of the

cutting process

Tooling Benchmark 2019

FiberCut III16 CFRP parts

4 different technologies

CFRP Wet

Compression Molding

CFRP Resin Transfer

Molding

CFRP-Steel hybrid

CF Sheet Molding

Compound

https://www.compositesworld.com/articles/is-the-bmw-7-series-the-future-of-autocomposites

Development of a

simulation model

for the machining of FRP

Cu

ttin

ge

xp

erim

en

ts

with

CF

RP,

GF

RP,A

FR

P

an

dC

FR

P-T

ita

niu

m

Me

tro

log

ica

l in

ve

stig

atio

n

of

the

wo

rkp

iece

an

dto

ol

fun

da

me

nta

l in

ve

stig

atio

n

ort

ho

go

na

l cu

ttin

g

Assembly of the task force FiberCut

as a discussion platform for innovative challenges

in the field of the machinability of fiber reinforced plastics.

IFT Institute for Production Engineering


Univ.Prof. DI Dr. techn. habil. Friedrich Bleicher

Institute for Production Engineering


Getreidemarkt 9/BA/8 OG

1060 Wien

T +43 1 58801 31101

E [email protected]

Contact person

CONTACT

Daniel Finkeldei, M.Sc.

Franz-Grill-Straße 4/Obj. 221/E311-1

A-1030 Vienna

T +43 1 58801 31112

E [email protected]

Jahresabschluss 2018 Workshop zum 3. Benchmark Results of … · 2019-06-24 · 2 Measurement of...

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