Analysis of potentials to improve the machining of hybrid workpieces
- 37 Downloads
Hybrid workpieces made of different materials are part of current research to investigate new design concepts for high-performance components. Cutting conditions and chip formation mechanisms change during machining based on different material properties and chemical compositions. This leads to different residual stresses in the subsurface, which influence the service life of the component. This paper examines the potential of improving workpiece quality and processing productivity of hybrid workpieces by material-specific machining. Furthermore, residual stress gradients in the transition zone were determined in order to analyze in further investigations its influence on the service behavior. The passive forces have a major influence on the residual stresses. By means of process parameter adaptation, the process forces can thus be specifically influenced and consequently the gradient in the material transition zone can be set therefore in a defined manner. For this purposes, the difference in process force during longitudinal turning of an aluminum–steel compound (EN-AW6082/20MnCr5) and a steel–steel compound (C22.8/41Cr4) was investigated. The resulting geometry errors, profile height deviation and surface roughness variance were measured for a wide parameter range and the residual stresses were compared for both material compounds. The optimization of the machining time through material-specific adaptation of the process parameters was calculated for six workpieces. The study shows the potential to reduce geometry errors and shorten the machining time for hybrid workpieces, if the process parameters are adapted to current machined material.
KeywordsTurning Optimization Hybrid parts Residual stress
The results presented in this paper were obtained within the Collaborative Research Centre 1153 “Process chain to produce hybrid high performance components by Tailored Forming” in the subprojects B4 and B5. The authors would like to thank the German Research Foundation (DFG) for the financial and organisational support of this project.
- 2.Fiebig S, Sellschopp J, Manz H, Vietor T, Axmann K, Schumacher A (2015) Future challenges for topology optimization for the usage in automotive lightweight design technologies. In: Proceedings of 11th world congress on structural and multidisciplinary optimization, Sydney, AustraliaGoogle Scholar
- 3.Behrens BA, Bouguecha A, Frischkorn C, Huskic A, Stakhieva A, Duran D (2016) Tailored forming technology for three dimensional components: approaches to heating and forming. In: 5th conference on thermomechanical processing, Milan, Italy, October 26th–28thGoogle Scholar
- 4.Behrens BA, Bouguecha A, Vucetic M, Peshekhodov I, Matthias T, Kolbasnikov N, Sokolov S, Ganin S (2016) Experimental investigations on the state of the friction-welded joint zone in steel hybrid components after process-relevant thermo-mechanical. In: AIP Conference Proceeding, vol 1769Google Scholar
- 6.Goldstein R, Behrens BA, Duran D (2017) Lightweighting by tailored forming: bi-material stepped shaft. In: Heat treat 2017, proceedings of the 29th ASM heat treating society conference, October 24–26, Columbus, Ohio, USAGoogle Scholar
- 7.Boehnke D (2007) Qualitätsorientierte Zerspanung von Parallelverbunden im kontinuierlichen Schnitt. Dissertation, Leibniz Universität HannoverGoogle Scholar
- 9.Klocke F, König W (2008) Fertigungsverfahren 1. Springer, BerlinGoogle Scholar
- 12.Denkena B, Bergmann B, Witt M (2017) Automatic process parameter adaption for hybrid workpieces during cylindrical operations. Int J Adv Manuf Technol 95(1–4):311–316Google Scholar