Lightweight and vibration reduced hybrid FRP-metal drill tubes with structure-integrated sensor technology for BTA deep hole drilling processes

轻量化、减振混合 FRP-金属钻管，采用结构集成传感器技术，适用于 BTA 深孔钻削工艺

• 批准号: 426328330
• 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: Research Grants (Transfer Project)
• 财政年份: 2019
• 资助国家: 德国
• 起止时间: 2018-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/426328330?language=en
• 关键词: Lightweight; vibration; reduced; hybrid; FRP

BTA deep drilling is a process for producing bores with high length-to-diameter ratios. However, the required tool lengths lead to an increased tendency of the tool system to vibrate. Strong torsional vibrations during drilling, which occur primarily during the machining of high-alloy materials, lead to increased wear of the cutting edges and guide pads as well as to a reduced drilling quality. An improvement of the dynamic behavior through the vibration damping resulting from the inhomogeneous structure of fiber-reinforced plastics (FRP) increases the process reliability and thus has a large market potential due to the typically high component costs. Based on promising preliminary investigations, a hybrid FRP drill tube is therefore to be developed in this project. In addition to the experience gained from basic investigations on BTA deep drilling (ISF) and the experience gained in the manufacture, use and metrological monitoring of metal CFRP lightweight structures within the framework of the priority programme "Intrinsic hybrid composites for lightweight structures" (LKT, Fraunhofer IZFP), the cooperation with the companies CarboFibretec, BGTB and Kaiser Maschinenbau und Zerspanungstechnik ensures the support and the expertise of industrial partners from the development, design and manufacture of the drill tube up to the application and validation.In addition to the direct influence on the deep drilling process and thus on tool wear and hole quality, the development of the FRP drill tube also focuses on the material-specific properties of fibre composites (laminate structure, coolant lubricant influence, hybrid connecting elements) and the sensory recording of the loads acting in the composite in order to qualify it for industrial use. The use of FRP for tool systems requires investigations of the interactions of the matrix and the fibres with other machine components, e.g. in the area of seals or contact points on the damping system, as well as with coolants and chips. In addition, for the use of structure-integrated sensor technology, the fibre winding process must be developed with regard to the connection of the sensor fibres with as little influence as possible on the fibre composite. Within the framework of the project, comprehensive experimental and simulation-supported investigations are carried out to optimize vibration and to adapt the laminate structure to the cutting process. Corrosion processes in direct contact between fibres and metal require the development of hybrid joining systems for the permanent bonding of metallic components. With the help of a data line to sensors in the drill head and sensors in the laminate of the drill tube, the process-parallel recording of important process variables and critical load cases and thus a condition monitoring of the tool system are investigated.

BTA深钻孔是生产具有高长度与直径比的孔的过程。但是，所需的刀具长度导致工具系统振动的趋势增加。钻孔过程中主要发生的强大扭转振动，主要发生在高合金材料的加工过程中，导致切割边缘和导板的磨损增加，以及降低的钻孔质量。通过纤维增强塑料（FRP）导致的振动阻尼来改善动态行为，从而提高了过程的可靠性，因此由于典型的组件成本高，因此具有较大的市场潜力。 基于有希望的初步研究，因此将在该项目中开发混合FRP钻管。除了从BTA深钻（ISF）的基本研究中获得的经验以及在优先计划“轻量级混合复合材料的轻量级结构”框架内对金属CFRP轻量级结构的制造，使用和计量监控所获得的经验，但与CARBRET IZFP CORPORETORTION”（LKT，FRAUNHHOFER IZFP） Maschinenbau und Zerspanungstechnik ensures the support and the expertise of industrial partners from the development, design and manufacture of the drill tube up to the application and validation.In addition to the direct influence on the deep drilling process and thus on tool wear and hole quality, the development of the FRP drill tube also focuses on the material-specific properties of fibre composites (laminate structure, coolant lubricant influence, hybrid connecting元素）和在复合材料中作用的负载的感官记录，以便将其用于工业用途。 FRP用于工具系统需要研究矩阵和纤维与其他机器组件的相互作用，例如在阻尼系统上的密封或接触点以及冷却剂和芯片的区域中。此外，对于使用结构集成的传感器技术，必须开发有关传感器纤维对纤维复合材料尽可能少的影响的纤维绕组过程。在项目的框架内，进行了全面的实验和模拟支持的研究，以优化振动并使层压板结构适应切割过程。纤维与金属之间直接接触的腐蚀过程需要开发混合连接系统，以永久粘结金属成分。借助数据线对钻头层压板的钻头和传感器中的传感器，研究重要过程变量和临界负载案例的过程并行记录，从而研究了对工具系统的条件监测。