Experimental and FEM-based Analysis of the thermal loads in deep-hole drilling process using twist drills and MQL

使用麻花钻和 MQL 进行深孔钻削过程中热载荷的实验和基于 FEM 的分析

• 批准号: 178784593
• 负责人: Professor Dr.-Ing. Dirk Biermann
• 金额: --
• 依托单位: Institut für Spanende Fertigung
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2010
• 资助国家: 德国
• 起止时间: 2009-12-31 至 2016-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/178784593?language=en
• 关键词: Experimental; FEM; based; Analysis; thermal

The main aim of this project is the development of a high-efficient finite-element-simulation, in order to predict the thermally induced workpiece deviations in deep-hole drilling of complex aluminium cast alloy components using twist drills and minimum quantity lubrication (MQL) as well as to develop appropriate compensation strategies and to minimize the experimental effort. Due to this central objective, two different focuses have been defined within this third and last stage of the priority program (PP) 1480. The first emphasis is the implementation of a high-precision and with regard to the computing time optimized 3d-simulation of the drilling process, in order to achieve realistic calculated thermally and mechanically induced workpiece deformations during and after the machining process. Further enhancements of the model should also be able to map the borehole straightness deviation which remains after cooling down of the workpiece. The second aim of the project is the development of three innovative compensation techniques, which are fundamentally different and offer diverse advantages and disadvantages so that a combination of the strategies seems to be reasonable, too. At first, the process adaptation of the feed / the feed velocity / should be analyzed, since a higher feed rate not only induces a lower thermal load into the workpiece, but also allows higher productivity. In terms of the coolant concept, the MQL should be used furthermore within the project. The compensation of the thermal load is carried out by cooled compressed air, which is a reasonable alternative to the cryogenic concept, because of its advantages regarding to the handling, operational safety etc. Cryogenic cooling is frequently used in machining of hard-to-cut materials. The third compensation strategy is based on the synchronous radial movement of the machine tool spindle during the axial feed of the tool. Due to this NC-path compensation, the drilling axis can be modified over the machining process and the drilling direction can be controlled. Apart from the fundamental investigation of these compensation techniques the developed solutions will be transferred to complex application oriented demonstration components. At the end of this third and last stage of this project within the PP 1480 a holistic methodology of the analysis, modelling, simulation, prediction, and compensation of the thermally induced workpiece deviations will be presented.

该项目的主要目的是开发高效的有限元仿真，以预测使用扭动钻机和最小数量润滑（MQL）的复杂铝制铸造合金组件进行热孔钻孔的热诱导工件偏差，以制定适当的补偿策略并最小化实验性努力。由于这个中心目标，在优先计划的第三阶段和最后阶段中定义了两个不同的焦点。第一个重点是实施高精度，并且在计算时间优化了钻孔过程的3D示例过程中，以实现在和机械诱导的在加工过程中和机械诱导的工件变形过程。该模型的进一步增强还应该能够绘制井眼直偏偏差，后者在制冷的工件冷却后仍保留。该项目的第二个目的是开发三种创新的补偿技术，这些技术在根本上是不同的，并提供了各种优势和缺点，因此策略的结合似乎也是合理的。首先，应分析进料 /进料速度 /的过程适应，因为较高的进料速率不仅诱导了较低的热载载量进入工件，而且还可以提高生产率。就冷却液概念而言，该项目还应在项目中使用。热负荷的补偿是通过冷却的压缩空气进行的，这是低温概念的合理替代品，因为它在处理，操作安全性等方面具有优势。低温冷却经常用于加工难以切割的材料。第三个补偿策略基于工具轴轴向进料期间机床的同步径向运动。由于这种NC路径补偿，可以在加工过程中修改钻孔轴，并且可以控制钻孔方向。除了对这些补偿技术的基本调查外，开发的解决方案还将转移到面向复杂的应用示范组件中。在PP 1480中，该项目的第三阶段也是最后一个阶段的结尾，将提出分析，建模，模拟，预测和补偿的整体方法论。