Hybrid manufacturing processes are known for combining the advantages of additive manufacturing and more traditional manufacturing processes such as machining to create components of complex geometry while minimising material waste. The trend towards lightweight design, especially in view of e-mobility, gives aluminium materials an important role to play. This study examines the use of aluminium alloys in laser metal wire deposition (LMWD) processes with subsequent subtractive machining, which is considerably more difficult due to the different process-related influences. The investigations are focussed on the influence of the differently controlled laser power on the shape accuracy, the microstructure, and the hardness of the AlMg5 test components after the LMWD process with subsequent subtractive machining by turning. The long-term goal of the investigations is to increase the stability of the hybrid production process of AlMg5 components with defined dimensional accuracy and mechanical properties.
The simulation of machining processes holds the opportunity for process improvement on many levels. Possible benefits that can be derived from accurate representations of the real processes on the tool from simulations include a prediction of tool wear, the shape of the chips produced, the forces, frictions and temperatures that arise and the residual stresses in the workpiece. These predictions can be used to improve the process in terms of its economic and ecological behaviour: Increasing the service life of the tools used through an improved understanding of the tool-workpiece interaction. The finite element method (FEM), among others, has emerged as a common method for simulating these processes. When simulating machining processes using FEM, a major challenge is to avoid or compensate for the mesh distortions caused by the massive, fast-moving deformation processes, but at the same time to allow the mesh to be discretised in some way to ensure chip removal. To this end, various approaches will be presented in the course of this work and the mesh-based approaches will be explored in depth. Among other things, a remeshing approach for these investigations was developed. The machining of TI6AL4V is used to illustrate these approaches, as its tendency to form segmented chips is particularly challenging to model.
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