In powder bed-based additive manufacturing (AM), complex geometries can be produced in a layer-wise approach. Results of material science experiments regarding material property identification, e.g., tensile strength, show interdependencies between the test load direction and the layer orientation. This goes hand-in-hand with the measured cutting force, changing with the relative angle between cutting direction and layer orientation in orthogonal cutting tests. However, due to the specific process characteristics, the layer orientation results in anisotropic material properties. Therefore, during machining, the material behaves depending on the buildup direction, which influences the cutting process. To predict this behavior, a simplified inverse approach is developed to determine the buildup direction-dependent parameters of a modified Johnson–Cook model for cutting simulation. To qualify these cutting models, mainly the cutting force and additionally the chip formation examined during orthogonal cuts are used. In the present paper, the influence of the laser-powder-bed-fusion (LPBF) process parameters on subtractive post-processing are shown. A good agreement between verification experiments and simulations is achieved.

Beim Sägen gelangt je nach Abschattung der Zerspanungszone durch das Bauteil, Werkzeug beziehungsweise anfallende Späne nur ein Bruchteil der eingesetzten KSS-Menge in die Zwischenräume von Span, Werkzeug und Werkstück. Eine innere Kühlschmiermittelzufuhr (IKZ) kann eine sichere KSS-Versorgung ermöglichen. Dieser Beitrag zeigt, wie erstmalig der Spanbildungsprozess in Interaktion mit einem Fluid im engen geschlossenen Schnittspalt beim Sägen sichtbar gemacht wird. Dies erlaubt die experimentelle Untersuchung thermischer und mechanischer Fluid-Festkörper-Wechselwirkungen im Sägeprozesses. In sawing, only a small amount of coolant reaches the spaces between the chip, tool and workpiece, depending on the shading of the cutting zone by the workpiece, tool or chips. An internal coolant supply (ICS) can enable a reliable coolant supply. For the first time, this paper shows how the chip formation process is made visible in interaction with a fluid in the narrow closed cutting gap during sawing. This enables the experimental investigation of thermal and mechanical fluid-solid interactions in the sawing process.

Häufig ist der Trennprozess von Halbzeugen mittels Bandsägen der erste Schritt in der Teilefertigung. Aufgrund bisher fehlender simulativer Untersuchungen wurden die Bearbeitungsparameter für diesen Prozess meist aufwendig experimentell ermittelt. Mit Analogieversuchen, die den zugrunde liegenden Prozess weitestgehend abdecken und mit viel geringerem Aufwand durchgeführt werden können, kann dies effizienter gestaltet werden. Der Beitrag untersucht, wie diese Versuche durch künstliche Intelligenz (KI) unterstützt und sich die Anzahl notwendiger Versuche reduzieren lassen. The cutting process of semi-finished products by means of band saws is often the first step in producing parts. So far, the lack of simulative investigations usually meant that machining parameters for this process had to be determined experimentally at great expense. This can be done more efficiently by means of analogy tests. They cover most of the underlying process and are more easily executed. This article examines the extent to which artificial intelligence (AI) can be used to support these experiments and reduce the number of experiments required.