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@PHDTHESIS{Ganser:1012485,
author = {Ganser, Philipp},
othercontributors = {Bergs, Thomas and Biermann, Dirk},
title = {{A}daptive milling of free-form surfaces with circle
segment end mills; 1. {A}uflage},
volume = {2025,6},
school = {RWTH Aachen University},
type = {Dissertation},
address = {Aachen},
publisher = {Apprimus Verlag},
reportid = {RWTH-2025-05016},
isbn = {978-3-98555-274-0},
series = {Innovations in manufacturing technology},
pages = {1 Online-Ressource : Illustrationen},
year = {2025},
note = {Druckausgabe: 2025. - Auch veröffentlicht auf dem
Publikationsserver der RWTH Aachen University; Dissertation,
RWTH Aachen University, 2024},
abstract = {Due to its high geometric flexibility, productivity and
achievable product quality, milling is a key technology in
metalworking and is widely used in industries such as
aerospace, die and mold making, or semiconductor industries.
In milling, increasingly complex product designs and rising
quality requirements are leading to the growing use of
5-axis milling processes. The state of the art in finishing
milling of complex features such as free-form surfaces is
milling with ball end mills, which offer high geometric
flexibility but have limited productivity due to the short
step-over distance required for sufficient surface quality.
An alternative is milling with so-called circle segment end
mills, also known as barrel tools, characterised by a
lateral circle segment contour with a significantly larger
radius compared to a standard ball end mill. Circle segment
end mills enable a significant increase in productivity due
to larger step-over distances with the same or even better
surface quality. However, circle segment end mills have so
far only been used to a limited extent by industrial end
users. The main reasons for the low level of acceptance are
complex tool design and tool path calculation, as well as
strong fluctuations in machinability criteria such as
process forces, particularly on free-form surfaces. Against
the background described, this thesis investigates
approaches for the adaptive milling of free-form surfaces
with circle segment end mills, in particular to reduce
fluctuations in the machinability criteria. In basic milling
tests, the machinability criteria are investigated as a
function of different surface topographies and process
parameters and compared with ball end milling. For the
simulation of milling operations with circle segment end
mills, a high-precision mechanistic engagement and force
simulation is modified and subjected to a comprehensive
validation and sensitivity study with regard to different
model configurations and calibration approaches. Using the
simulation capabilities obtained, the causes of variations
in machinability criteria are identified, suitable process
rules for their avoidance are derived and implemented in
adaptive milling strategies, supported by corresponding
aspects of tool path calculation. The validation of the
CAM-integrated, adaptive milling strategies is carried out
using a free-form surface demonstrator. The work presented
is intended to support the industrial use of circle segment
end mills.},
cin = {417410 / 417400 / 053200},
ddc = {620},
cid = {$I:(DE-82)417410_20140620$ / $I:(DE-82)417400_20240301$ /
$I:(DE-82)053200_20140620$},
pnm = {FlexiMill – A Technology Platform for the Fast and
Flexible Machining of Freeform Surfaces using Circle Segment
End Mills (E!10874)},
pid = {G:(EUREKA)E!10874},
typ = {PUB:(DE-HGF)11 / PUB:(DE-HGF)3},
doi = {10.18154/RWTH-2025-05016},
url = {https://publications.rwth-aachen.de/record/1012485},
}
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