Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten

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1. Verfasser: Maslo, Semir (VerfasserIn)
Format: Abschlussarbeit Buch
Sprache:English
Veröffentlicht: Aachen Apprimus Verlag 2022
Ausgabe:1. Auflage
Schriftenreihe:Ergebnisse aus der Produktionstechnik Band 24/2022
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Datensatz im Suchindex

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adam_text CONTENT INHALTSVERZEICHNIS 1 INTRODUCTION ................................................................................................................ 1 2 FUNDAMENTALS AND STATE OF THE ART ........................................................................ 5 2.1 TECHNOLOGY OF THE MILLING PROCESS .................................................................... 5 2.1.1 DEFINITION AND CLASSIFICATION OF THE MILLING PROCESS ........................... 5 2.1.2 ENGAGEMENT CONDITIONS IN 5 AXIS-MILLING ........................................... 6 2.1.3 CUTTING FORCE CALCULATION ................................................................... 10 2.2 DYNAMIC PROCESS STABILITY ............................................................................... 12 2.2.1 OCCURRENCE OF VIBRATIONS IN THE MILLING PROCESS .............................. 12 2.2.2 DYNAMIC STRUCTURAL MODELS ................................................................. 14 2.2.3 ILLUSTRATIONS OF THE FREQUENCY RESPONSE FUNCTION FRF ................... 18 2.2.4 TYPES OF VIBRATIONS IN THE MILLING PROCESS ........................................ 20 2.2.5 REGENERATIVE CHATTER ...................... , .................................................. 22 2.2.6 POSSIBILITIES FOR VIBRATION REDUCTION ................................................. 25 2.3 SIMULATION OF THE IN-PROCESS-WORKPIECE DYNAMICS ...................................... 29 3 OBJECTIVES AND PROCEDURE OF THE THESIS ............................................................. 35 3.1 OBJECTIVES AND RESEARCH METHODOLOGY ......................................................... 35 3.2 PROCEDURE AND SETUP OF THE THESIS ............................................................... 37 4 VIBRATION SIMULATION OF A PLATE GEOMETRY ........................................................... 39 4.1 SIMULATION PROCEDURE 3-AXIS MILLING ............................................................... 39 4.2 DEFINITION OF A PLATE DEMONSTRATOR AND PROCESS PLANNING ............................ 40 4.2.1 PLATE DEMONSTRATOR GEOMETRY AND PROCESS SETUP ........................... 40 4.2.2 PLATE MATERIAL ANALYSIS TI-6AI-4V ...................................................... 41 4.2.3 DEFINITION OF DISCRETE PLATE SIMULATION POINTS .................................. 42 4.3 DEVELOPMENT OF A CUTTING FORCE EXCITATION MODEL ......................................... 42 4.3.1 PROCEDURE OF A CUTTING FORCE SIMULATION .......................................... 43 4.3.2 EXPERIMENTAL DETERMINATION OF THE SPECIFIC CUTTING FORCE ............. 44 4.3.3 DESCRIPTION OF THE CUTTING FORCE IN DEPENDENCY OF THE SPINDLE ROTATION .............................................................................................. 46 4.4 MODAL ANALYSIS RAW PLATE GEOMETRY .............................................................. 48 4.4.1 PERFORMANCE OF EXPERIMENTAL MODAL ANALYSIS EMA ......................... 48 4.4.2 ANALYSIS OF THE EXPERIMENTALLY OBTAINED COMPLIANCE OF THE RAW PLATE ..................................................................................................... 50 4.4.3 FRF SIMULATION OF THE RAW PLATE GEOMETRY ...................................... 52 4.4.4 COMPARISON OF SIMULATED AND EXPERIMENTALLY OBTAINED DYNAMIC COMPLIANCE FOR THE RAW PLATE GEOMETRY ......................................... 56 4.4.5 ANALYSIS OF THE NUMBER OF EIGENMODES TO BE CONSIDERED ............. 60 4.5 DEVELOPMENT OF A PLATE DYNAMIC MODEL ........................................................ 61 4.5.1 GEOMETRICAL REPRESENTATION IN-PROCESS-WORKPIECE PLATE ............. 62 4.5.2 PARAMETRIC FE MODAL ANALYSES OF THE PLATE .................................... 63 4.5.3 DYNAMIC LINEAR-PARAMETRIC-VARYING (LPV) PLATE MODEL ................. 64 VIII CONTENT 4.5.4 ANALYSIS OF CHANGING PLATE DYNAMICS .............................................. 66 4.5.5 COMPLIANCE INTERPOLATION ANALYSIS WITH THE LPV-MODEL ................. 72 4.6 DEVELOPMENT OF THE TOOL DYNAMICS MODEL .................................................... 76 4.7 TIME-DOMAIN VIBRATION MODEL FOR A 3-AXIS MILLING PROCESS ......................... 81 4.8 GENERATION OF A PLATE STABILITY DIAGRAM ......................................................... 84 4.9 SUMMARY AND INTERMEDIATE CONCLUSION ......................................................... 85 5 VALIDATION OF THE PLATE STABILITY DIAGRAM ............................................................ 87 5.1 VALIDATION OF THE PLATE STABILITY DIAGRAM AND SELECTION OF SPINDLE ROTATIONAL FREQUENCIES ....................................................................................................... 87 5.2 EXPERIMENTAL SETUP OF THE PLATE VALIDATION TRIALS ......................................... 89 5.3 ANALYSIS OF THE PLATE VALIDATION TRIALS ............................................................ 90 5.4 SUMMARY AND INTERMEDIATE CONCLUSIONS ....................................................... 94 6 VIBRATION SIMULATION OF A BLISK ............................................................................. 97 6.1 SIMULATION PROCEDURE 5 AXIS MILLING ............................................................... 97 6.2 DEFINITION OF THE BLISK DEMONSTRATOR AND PROCESS PLANNING ......................... 97 6.2.1 BLISK DEMONSTRATOR GEOMETRY AND PROCESS SETUP .......................... 98 6.2.2 DEFINITION OF DISCRETE BLISK SIMULATION POINTS ................................... 99 6.3 CUTTING FORCE SIMULATION DURING 5-AXIS-MILLING IN DEPENDENCY OF THE SPINDLE ROTATIONAL FREQUENCY ..................................................................................... 100 6.4 DEVELOPMENT OF THE BLISK DYNAMICS MODEL ................................................... 102 6.4.1 GEOMETRICAL REPRESENTATION OF THE IN-PROCESS-WORKPIECE .......... 102 6.4.2 PARAMETRIC FE MODAL ANALYSES OF BLISK ........................................... 105 6.4.3 SHRINK-WRAP MESH AND FE MODAL SIMULATION TIME ANALYSIS ....... 106 6.4.4 DYNAMIC LINEAR-PARAMETRIC-VARYING (LPV) BLISK MODEL ................ 111 6.4.5 ANALYSIS OF THE CHANGING BLISK DYNAMICS ........................................ 111 6.5 COMPARISON SIMULATED AND EXPERIMENTAL-OBTAINED COMPLIANCE ............... 116 6.6 TIME-DOMAIN VIBRATION MODEL FOR A 5 AXIS MILLING PROCESS ......................... 119 6.7 GENERATION OF A BLISK STABILITY DIAGRAM ....................................................... 121 6.8 SUMMARY AND INTERMEDIATE CONCLUSIONS ..................................................... 122 7 VALIDATION OF THE BLISK STABILITY DIAGRAM ...........................................................125 7.1 VALIDATION OF THE BLISK STABILITY DIAGRAM AND SELECTION OF SPINDLE ROTATIONAL FREQUENCIES ..................................................................................................... 125 7.2 EXPERIMENTAL SETUP OF THE BLISK VALIDATION TRIALS ........................................ 128 7.3 ANALYSIS OF THE BLISK VALIDATION TRIALS ........................................................... 130 7.4 SUMMARY AND INTERMEDIATE CONCLUSIONS ...................................................... 138 8 SUMMARY AND OUTLOOK ........................................................................................... 141 9 REFERENCES ...............................................................................................................147 A APPENDIX .................................................................................................................. 161
adam_txt CONTENT INHALTSVERZEICHNIS 1 INTRODUCTION . 1 2 FUNDAMENTALS AND STATE OF THE ART . 5 2.1 TECHNOLOGY OF THE MILLING PROCESS . 5 2.1.1 DEFINITION AND CLASSIFICATION OF THE MILLING PROCESS . 5 2.1.2 ENGAGEMENT CONDITIONS IN 5 AXIS-MILLING . 6 2.1.3 CUTTING FORCE CALCULATION . 10 2.2 DYNAMIC PROCESS STABILITY . 12 2.2.1 OCCURRENCE OF VIBRATIONS IN THE MILLING PROCESS . 12 2.2.2 DYNAMIC STRUCTURAL MODELS . 14 2.2.3 ILLUSTRATIONS OF THE FREQUENCY RESPONSE FUNCTION FRF . 18 2.2.4 TYPES OF VIBRATIONS IN THE MILLING PROCESS . 20 2.2.5 REGENERATIVE CHATTER . , . 22 2.2.6 POSSIBILITIES FOR VIBRATION REDUCTION . 25 2.3 SIMULATION OF THE IN-PROCESS-WORKPIECE DYNAMICS . 29 3 OBJECTIVES AND PROCEDURE OF THE THESIS . 35 3.1 OBJECTIVES AND RESEARCH METHODOLOGY . 35 3.2 PROCEDURE AND SETUP OF THE THESIS . 37 4 VIBRATION SIMULATION OF A PLATE GEOMETRY . 39 4.1 SIMULATION PROCEDURE 3-AXIS MILLING . 39 4.2 DEFINITION OF A PLATE DEMONSTRATOR AND PROCESS PLANNING . 40 4.2.1 PLATE DEMONSTRATOR GEOMETRY AND PROCESS SETUP . 40 4.2.2 PLATE MATERIAL ANALYSIS TI-6AI-4V . 41 4.2.3 DEFINITION OF DISCRETE PLATE SIMULATION POINTS . 42 4.3 DEVELOPMENT OF A CUTTING FORCE EXCITATION MODEL . 42 4.3.1 PROCEDURE OF A CUTTING FORCE SIMULATION . 43 4.3.2 EXPERIMENTAL DETERMINATION OF THE SPECIFIC CUTTING FORCE . 44 4.3.3 DESCRIPTION OF THE CUTTING FORCE IN DEPENDENCY OF THE SPINDLE ROTATION . 46 4.4 MODAL ANALYSIS RAW PLATE GEOMETRY . 48 4.4.1 PERFORMANCE OF EXPERIMENTAL MODAL ANALYSIS EMA . 48 4.4.2 ANALYSIS OF THE EXPERIMENTALLY OBTAINED COMPLIANCE OF THE RAW PLATE . 50 4.4.3 FRF SIMULATION OF THE RAW PLATE GEOMETRY . 52 4.4.4 COMPARISON OF SIMULATED AND EXPERIMENTALLY OBTAINED DYNAMIC COMPLIANCE FOR THE RAW PLATE GEOMETRY . 56 4.4.5 ANALYSIS OF THE NUMBER OF EIGENMODES TO BE CONSIDERED . 60 4.5 DEVELOPMENT OF A PLATE DYNAMIC MODEL . 61 4.5.1 GEOMETRICAL REPRESENTATION IN-PROCESS-WORKPIECE PLATE . 62 4.5.2 PARAMETRIC FE MODAL ANALYSES OF THE PLATE . 63 4.5.3 DYNAMIC LINEAR-PARAMETRIC-VARYING (LPV) PLATE MODEL . 64 VIII CONTENT 4.5.4 ANALYSIS OF CHANGING PLATE DYNAMICS . 66 4.5.5 COMPLIANCE INTERPOLATION ANALYSIS WITH THE LPV-MODEL . 72 4.6 DEVELOPMENT OF THE TOOL DYNAMICS MODEL . 76 4.7 TIME-DOMAIN VIBRATION MODEL FOR A 3-AXIS MILLING PROCESS . 81 4.8 GENERATION OF A PLATE STABILITY DIAGRAM . 84 4.9 SUMMARY AND INTERMEDIATE CONCLUSION . 85 5 VALIDATION OF THE PLATE STABILITY DIAGRAM . 87 5.1 VALIDATION OF THE PLATE STABILITY DIAGRAM AND SELECTION OF SPINDLE ROTATIONAL FREQUENCIES . 87 5.2 EXPERIMENTAL SETUP OF THE PLATE VALIDATION TRIALS . 89 5.3 ANALYSIS OF THE PLATE VALIDATION TRIALS . 90 5.4 SUMMARY AND INTERMEDIATE CONCLUSIONS . 94 6 VIBRATION SIMULATION OF A BLISK . 97 6.1 SIMULATION PROCEDURE 5 AXIS MILLING . 97 6.2 DEFINITION OF THE BLISK DEMONSTRATOR AND PROCESS PLANNING . 97 6.2.1 BLISK DEMONSTRATOR GEOMETRY AND PROCESS SETUP . 98 6.2.2 DEFINITION OF DISCRETE BLISK SIMULATION POINTS . 99 6.3 CUTTING FORCE SIMULATION DURING 5-AXIS-MILLING IN DEPENDENCY OF THE SPINDLE ROTATIONAL FREQUENCY . 100 6.4 DEVELOPMENT OF THE BLISK DYNAMICS MODEL . 102 6.4.1 GEOMETRICAL REPRESENTATION OF THE IN-PROCESS-WORKPIECE . 102 6.4.2 PARAMETRIC FE MODAL ANALYSES OF BLISK . 105 6.4.3 SHRINK-WRAP MESH AND FE MODAL SIMULATION TIME ANALYSIS . 106 6.4.4 DYNAMIC LINEAR-PARAMETRIC-VARYING (LPV) BLISK MODEL . 111 6.4.5 ANALYSIS OF THE CHANGING BLISK DYNAMICS . 111 6.5 COMPARISON SIMULATED AND EXPERIMENTAL-OBTAINED COMPLIANCE . 116 6.6 TIME-DOMAIN VIBRATION MODEL FOR A 5 AXIS MILLING PROCESS . 119 6.7 GENERATION OF A BLISK STABILITY DIAGRAM . 121 6.8 SUMMARY AND INTERMEDIATE CONCLUSIONS . 122 7 VALIDATION OF THE BLISK STABILITY DIAGRAM .125 7.1 VALIDATION OF THE BLISK STABILITY DIAGRAM AND SELECTION OF SPINDLE ROTATIONAL FREQUENCIES . 125 7.2 EXPERIMENTAL SETUP OF THE BLISK VALIDATION TRIALS . 128 7.3 ANALYSIS OF THE BLISK VALIDATION TRIALS . 130 7.4 SUMMARY AND INTERMEDIATE CONCLUSIONS . 138 8 SUMMARY AND OUTLOOK . 141 9 REFERENCES .147 A APPENDIX . 161
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author Maslo, Semir
author_facet Maslo, Semir
author_role aut
author_sort Maslo, Semir
author_variant s m sm
building Verbundindex
bvnumber BV048254135
classification_rvk ZL 5400
ctrlnum (OCoLC)1322809263
(DE-599)DNB1258392097
discipline Maschinenbau / Maschinenwesen
discipline_str_mv Maschinenbau / Maschinenwesen
edition 1. Auflage
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illustrated Illustrated
index_date 2024-07-03T19:57:48Z
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institution BVB
institution_GND (DE-588)1068101474
isbn 9783985550821
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language English
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physical XI, 180 Seiten Illustrationen, Diagramme 21 cm x 14.8 cm, 274 g
publishDate 2022
publishDateSearch 2022
publishDateSort 2022
publisher Apprimus Verlag
record_format marc
series Ergebnisse aus der Produktionstechnik
series2 Ergebnisse aus der Produktionstechnik
Prozesstechnologie
spelling Maslo, Semir Verfasser aut
Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten Semir Maslo
Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten
1. Auflage
Aachen Apprimus Verlag 2022
XI, 180 Seiten Illustrationen, Diagramme 21 cm x 14.8 cm, 274 g
txt rdacontent
n rdamedia
nc rdacarrier
Ergebnisse aus der Produktionstechnik Band 24/2022
Prozesstechnologie
Dissertation Rheinisch-Westfälische Technische Hochschule Aachen 2022
Fräsen (DE-588)4018037-2 gnd rswk-swf
Strömungsmechanik (DE-588)4077970-1 gnd rswk-swf
Mehrachsigkeit (DE-588)4425343-6 gnd rswk-swf
Prozesssimulation (DE-588)4176077-3 gnd rswk-swf
Blisk (DE-588)7606328-8 gnd rswk-swf
Werkstück (DE-588)4128997-3 gnd rswk-swf
Schwingungsverhalten (DE-588)4180569-0 gnd rswk-swf
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Strömungsmaschine (DE-588)4058079-9 gnd rswk-swf
Winkelgeschwindigkeit (DE-588)4265086-0 gnd rswk-swf
Schwingung (DE-588)4053999-4 gnd rswk-swf
Dünnwandigkeit (DE-588)4150840-3 gnd rswk-swf
Werkzeugmaschinen
Prozessstabilität
Zerspantechnologie
Maschinendatenanalyse
Hochleistungszerspanung
Fertigungstechnik
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DE-604
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Blisk (DE-588)7606328-8 s
Dünnwandigkeit (DE-588)4150840-3 s
Schwingung (DE-588)4053999-4 s
Fräsen (DE-588)4018037-2 s
Mehrachsigkeit (DE-588)4425343-6 s
Frässpindel (DE-588)4113603-2 s
Winkelgeschwindigkeit (DE-588)4265086-0 s
Prozesssimulation (DE-588)4176077-3 s
Apprimus Verlag (DE-588)1068101474 pbl
Ergebnisse aus der Produktionstechnik Band 24/2022 (DE-604)BV023307578 2022,24
DNB Datenaustausch application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=033634409&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis
1\p vlb 20220525 DE-101 https://d-nb.info/provenance/plan#vlb
spellingShingle Maslo, Semir
Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten
Ergebnisse aus der Produktionstechnik
Fräsen (DE-588)4018037-2 gnd
Strömungsmechanik (DE-588)4077970-1 gnd
Mehrachsigkeit (DE-588)4425343-6 gnd
Prozesssimulation (DE-588)4176077-3 gnd
Blisk (DE-588)7606328-8 gnd
Werkstück (DE-588)4128997-3 gnd
Schwingungsverhalten (DE-588)4180569-0 gnd
Frässpindel (DE-588)4113603-2 gnd
Strömungsmaschine (DE-588)4058079-9 gnd
Winkelgeschwindigkeit (DE-588)4265086-0 gnd
Schwingung (DE-588)4053999-4 gnd
Dünnwandigkeit (DE-588)4150840-3 gnd
subject_GND (DE-588)4018037-2
(DE-588)4077970-1
(DE-588)4425343-6
(DE-588)4176077-3
(DE-588)7606328-8
(DE-588)4128997-3
(DE-588)4180569-0
(DE-588)4113603-2
(DE-588)4058079-9
(DE-588)4265086-0
(DE-588)4053999-4
(DE-588)4150840-3
(DE-588)4113937-9
title Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten
title_alt Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten
title_auth Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten
title_exact_search Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten
title_exact_search_txtP Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten
title_full Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten Semir Maslo
title_fullStr Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten Semir Maslo
title_full_unstemmed Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten Semir Maslo
title_short Simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components
title_sort simulation of the dynamic vibration behaviour and spindle speed optimization during the milling process of turbomachinery components simulation des dynamischen schwingungsverhaltens und optimierung der spindeldrehzahl beim frasen von turbomaschinen komponenten
title_sub = Simulation des dynamischen Schwingungsverhaltens und Optimierung der Spindeldrehzahl beim Fräsen von Turbomaschinen-Komponenten
topic Fräsen (DE-588)4018037-2 gnd
Strömungsmechanik (DE-588)4077970-1 gnd
Mehrachsigkeit (DE-588)4425343-6 gnd
Prozesssimulation (DE-588)4176077-3 gnd
Blisk (DE-588)7606328-8 gnd
Werkstück (DE-588)4128997-3 gnd
Schwingungsverhalten (DE-588)4180569-0 gnd
Frässpindel (DE-588)4113603-2 gnd
Strömungsmaschine (DE-588)4058079-9 gnd
Winkelgeschwindigkeit (DE-588)4265086-0 gnd
Schwingung (DE-588)4053999-4 gnd
Dünnwandigkeit (DE-588)4150840-3 gnd
topic_facet Fräsen
Strömungsmechanik
Mehrachsigkeit
Prozesssimulation
Blisk
Werkstück
Schwingungsverhalten
Frässpindel
Strömungsmaschine
Winkelgeschwindigkeit
Schwingung
Dünnwandigkeit
Hochschulschrift
url http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=033634409&sequence=000001&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA
volume_link (DE-604)BV023307578
work_keys_str_mv AT maslosemir simulationofthedynamicvibrationbehaviourandspindlespeedoptimizationduringthemillingprocessofturbomachinerycomponentssimulationdesdynamischenschwingungsverhaltensundoptimierungderspindeldrehzahlbeimfrasenvonturbomaschinenkomponenten
AT apprimusverlag simulationofthedynamicvibrationbehaviourandspindlespeedoptimizationduringthemillingprocessofturbomachinerycomponentssimulationdesdynamischenschwingungsverhaltensundoptimierungderspindeldrehzahlbeimfrasenvonturbomaschinenkomponenten
AT maslosemir simulationdesdynamischenschwingungsverhaltensundoptimierungderspindeldrehzahlbeimfrasenvonturbomaschinenkomponenten
AT apprimusverlag simulationdesdynamischenschwingungsverhaltensundoptimierungderspindeldrehzahlbeimfrasenvonturbomaschinenkomponenten