Development of a combined simulation-model for the prediction of process- and machine-induced deviations of surface areas in broaching

开发组合仿真模型，用于预测拉削过程中工艺和机器引起的表面区域偏差

基本信息

批准号：
165937581
负责人：
Professor Dr.-Ing. Volker Schulze
金额：
--
依托单位：
Institut für Produktionstechnik (WBK)
依托单位国家：
德国
项目类别：
Research Grants
财政年份：
2010
资助国家：
德国
起止时间：
2009-12-31 至 2015-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/165937581?language=en
关键词：
Development combined simulation model prediction

项目摘要

This research project deals with the development of a holistic 3D-FEM-simulation model to assess the component quality influenced by the interactions of process and machine. Based on the simulation methodology developed in the initial application, it is now possible to extend the simulation model to internal broaching. At the begin, experimental studies aiming at analyzing the production process as well as finally validating the simulation model to be developed will be conducted. For this aim, the impact of minor cutting edges on process forces is evaluated by conducting tests with single-cutting tools in full section and comparing the force evolution to the values of the specific process forces. In a further step, the analytical model for predicting the specific process forces is extended by the cross force component to be able to calculate all the forces acting. This is necessary, since the work up to was focussed on external broaching and the production process was simulated with orthogonal cutting. To be able to replicate the machine dynamics as accurately as possible, it must be experimentally investigated how the machine interacts with the built-in internal broaching tool and the clamping of the workpiece. The machine model will be set up and validated. In the following work package, the machine model will be linked with the analytical model for calculating the specific forces. The coupling of the two models will take place at two interfaces: tool-process and process-workpiece. Afterwards, the developed simulation model will be validated with and if necessary adapted to the data generated in the first work package. In conclusion, the developed simulation methodology will be applied exemplarily to another production process in order to evaluate the methods adaptivity.

该研究项目涉及开发整体 3D-FEM 仿真模型，以评估受过程和机器相互作用影响的部件质量。基于最初应用中开发的仿真方法，现在可以将仿真模型扩展到内拉削。首先，将进行旨在分析生产过程并最终验证要开发的模拟模型的实验研究。为此，通过在全截面中使用单切削刀具进行测试并将力的演变与特定加工力的值进行比较来评估小切削刃对加工力的影响。在进一步的步骤中，用于预测特定过程力的分析模型通过横向力分量进行扩展，以能够计算所有作用力。这是必要的，因为之前的工作主要集中在外部拉削上，并且通过正交切削来模拟生产过程。为了能够尽可能准确地复制机床动态，必须通过实验研究机床如何与内置内拉刀和工件夹紧相互作用。将设置并验证机器模型。在接下来的工作包中，机器模型将与分析模型相链接以计算比力。两个模型的耦合将在两个接口处进行：工具-过程和过程-工件。随后，开发的仿真模型将使用第一个工作包中生成的数据进行验证，并在必要时进行调整。总之，所开发的模拟方法将被示例性地应用于另一个生产过程，以评估该方法的适应性。