Leichtbau von Fräsvorrichtungen

Translated title of the contribution: Lightweight design of milling fixtures

Josef Sauseng

Research output: ThesisMaster's Thesis

Abstract

High masses of fixtures, which are based on the demand for great functionality and flexibility, lead to challenges in highly dynamic milling processes. Within the scope of this work, lightweight design approaches were therefore examined with regard to their practicability for fixture construction. After the introductory literature research on fixtures and lightweight design strategies, an exemplary device for the milling of a forged part was optimized with regard to its lightweight construction potential. The five lightweight design strategies serve as a guideline for the approaches described. In the case of conditional lightweight design, consistent weighing of requirements was found to be the key to successful weight minimization. The considerations for concept lightweight design showed that consistent coordination with the machining strategy leads to an optimum selection and positioning of available clamping elements. In the course of lightweight material design, high static and dynamic stiffness as well as high damping capacity were described as the essential requirements for a fixture structure. Both low-alloy steels and mineral casting were found to be suitable materials. The topology optimization carried out in the context of form lightweight design showed that weight could be reduced to a large extent by targeted reduction of material at selected points and a force flow-oriented design. When considering lightweight manufacturing, a ribbed welded structure with mineral filling was found as the optimal solution for a weight-saving construction of the fixture base body. The optimization reduced the mass of the fixture by 67 %. In addition, both static and dynamic stiffness as well as the damping capacity were increased. Based on the described lightweight design approaches, a catalogue of recommendations with 14 general points for the future design of lightweight and cost-effective fixtures could be derived.
Translated title of the contributionLightweight design of milling fixtures
Original languageGerman
QualificationDipl.-Ing.
Awarding Institution
  • Montanuniversität
Supervisors/Advisors
  • Stockinger, Martin, Supervisor (internal)
Award date8 Apr 2022
Publication statusPublished - 2022

Bibliographical note

embargoed until 28-02-2027

Keywords

  • Lightweight design
  • fixtures
  • clamping fixtures
  • machining
  • milling

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