The trends of machining difficult-to-machine materials and of dry machining or MQL lead to high temperatures in the cutting zone and increase the importance of thermal factors in the machining process. Besides amplified thermal tool loading and wear, the thermal fluxes affect the machining accuracy due to thermo-elastic deformations. Thus it is extremely important to know the magnitudes of these heat flows in order to assess the machining process heat and the tool wear and to develop compensation strategies against thermal tool center point (TCP) displacements. Based on the FE modeling of the cutting processes, the paper describes methods of determining the generated thermal energy and heat fluxes. Furthermore, new methods are presented how and in which partitions this heat flows into the workpiece, the tool and the chips. In order to validate the methods, 2D FE models are compared with temperature and force measurements carried out on a broaching test bed. The methods are applied on cutting examples which are investigated in the papers of Komanduri and Hou using analytical models. Thus, the simulation allows an assessment of the heat fluxes in real cutting processes in comparison with analytical and simplified numerical models.
Air traffic is expected to double over the next 20 years and Flightpath 2050 targets to a 70 % reduction of CO2 and a 90 % reduction of NOx. Optimization of future aircraft engines often is dominantly driven by a focus on the reduction of fuel burn and emissions during operation. To identify additional environmental improvement potential a full Life Cycle Analysis (LCA) shall be aspired also including Materials, Processes and Resources, Manufacture and Production, Lifetime Services as well as Reuse, End-of-Life and Recycling. Core engine components, for example integral rotors, are comprised of Titanium-or Nickel-alloys and require complex manufacturing processes.
A geometry design model of a compressor blisk is introduced which is employed as basis for a future LCA approach focusing on materials, processes and resources as well as manufacture and production. The model is a carrier for challenging manufacturing features such as large blade twist, high aspect ratio and small blade gaps. In addition to the geometry model, a first set of multiple technology scenarios and their process chains will be introduced which will serve as base for a future LCA.
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