Untersuchungen zum Einfluss der durch moderne Fräsverfahren gefertigten Oberflächen auf die Ermüdung

FKM 2001
Issue No. 262
Project No. 220

Abstract:

Both conventional milling and high-speed machining were examined for the experimental investigation of the relationship between the machining process, the resulting surface layer condition on the component and its fatigue strength. This was based on machining parameters that are typical for mechanical engineering and relevant in practice. The corrosion-resistant steel X22CrMoV12.1 and the aluminum alloy AICu2MgNi were selected as sample materials. To determine the fatigue behavior as a result of different machining, single-stage Wöhler and fatigue strength tests were carried out on unnotched (Kt ~ 1.0) and component-like specimens (Kt ~ 1.4). To describe the condition of the component surfaces, X-ray residual stress measurements, laser-optical and tactile topography images and hardness measurements with the determination of hardness depth gradients were carried out. The test results can be summarized as follows: .in the parameter ranges investigated (vc, f, aeJ ap), it makes sense to take a service life restriction into account. Qualitative statements can be made about the influence of machining parameters on the fatigue strength of components (made of the investigated materials). Quantification is not yet possible. In order to achieve maximum productivity, the findings on component strength must be taken into account in the evaluation model. For the steel material X22CrMoV12.1, the machining parameters can be selected according to the maximum productivity criterion. There is no reduction in component fatigue strength. For the aluminum material AICu2MgNi, the estimability of the component fatigue strength was confirmed using the FKM guideline. The results show a major influence of the technological manufacturing conditions. A solution approach for a design concept was developed and demonstrated for both materials. The generalization of service life restrictions requires further investigations, especially for the manufacturing processes of turning and milling. The objective of the research project was achieved. Scope of report:
120 p., 118 ill., 22 tab., 48 lit. Start of work:
01.04.1997 End of work:
30.06.2000 Funding body:
BMWi/AiF-Nr. 11141 B Research centers:
IMA Materialforschung und Anwendungstechnik GmbH Dresden Managing Director:
Dr.-lng. W. Hanel Institute of Production Engineering, Dresden University of Technology Head:
Prof. Dr.-lng. habil U. Füssel Institute of Mechanical Plant Engineering and Structural Durability Clausthal University of Technology Head:
Prof. Dr.-lng. H. Zenner Processors and authors:
Prof. Dr.-lng. U. Günther, Dipl.-lng. W. Fessenmayer, Dipl.-lng. O. Krämer Dipl.-lng. Krämer Dipl.-lng. H. Mauch Chairman of the working group:
Dr.-lng. C. Gerdes, ABB Baden/Switzerland Chairman of the Advisory Board:
Dipl.-lng. J. Rabe, Sachsenring AG