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    Partitioning of primary shear zone heat in face milling
    The outcome of this paper allows calculating the fraction of heat generated in the primary shear zone that is transferred to the workpiece in face milling. The proposed approach is based on a sequentially coupled analysis of the heat partitioning in the cutting edge normal plane and in the reference plane. The latter, for the first time, allows to systematically take into account the removal of heated workpiece material by subsequent cutting tool engagements. The generated heat is related to the uncut chip thickness. Utilizing Weiner’s approach, the heat flux density distribution is determined which serves as input for a three-dimensional thermal finite element simulation that is validated experimentally by temperature measurements.
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      162  102
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    Influence of the workpiece material on the cutting performance in low frequency vibration assisted drilling
    Fundamental problems in drilling processes are associated with the unfavorable machining conditions in the tool center and the difficult chip removal. Low frequency vibration assisted drilling (LFVAD), in which the linear tool feed is superimposed with a vibratory motion in feed direction, is a promising process to overcome these problems. Aiming at a systematic analysis of the influence of workpiece material properties, results from LFVAD experiments with Ti6Al4V, AlMgSi0.5 and 42CrMo4 in different heat treatment states are presented. Specifically the dependence of optimal oscillation amplitudes on the workpiece material behavior is analyzed.
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      99  87
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    Analysis of internal material loads and Process Signature Components in deep rolling
    The high mechanical loads in deep rolling lead to a beneficial surface topography, hardness alterations, and compressive residual stresses. The generation of defined residual stress values has been achieved in a mainly iterative way, as the relevant internal material loads occurring during the process could not be considered. They are difficult to determine experimentally and well-validated models are required to deduce them e.g. from finite element (FE) simulations. In this study, a 3D FE model has been developed to analyze the strains in the workpiece material as a measure for the internal material load during the process. The residual stress profiles were measured by x-ray-diffraction and are presented in a way that allows for deriving the internal material loads required to induce a desired residual stress state.
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      255  155
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    An analytical multilayer source stress approach for the modelling of material modifications in machining
    In the research concept of Process Signatures machining induced changes of surface and sub-surface material properties are considered as material modifications caused by the physical conditions the material is exposed to during the process. This paper presents a newly developed multilayer source stress model to analytically describe the material modifications caused by the machining process in multiple passes. The analytical model that needs measured shape deviations as input is validated via finite element simulations. The approach incorporates the effects of machining induced source stresses and the contribution of residual stresses present in the workpiece before machining. Results from milling experiments show a pronounced correlation between the identified workpiece material modifications and the width of cut.
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      93  86