Fully coupled fluid-structure-contact simulations to understand the processes in the contact zones during lubricated orthogonal cutting

完全耦合的流体-结构-接触模拟，以了解润滑正交切削过程中接触区域的过程

• 批准号: 439919057
• 负责人: Professorin Dr.-Ing. Stefanie Elgeti
• 金额: --
• 依托单位: Institut für Leichtbau und Struktur-Biomechanik
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/439919057?language=en
• 关键词: Fully; coupled; fluid; structure; contact

In metal-cutting manufacturing, a particularly large sustainability potential can be found in reducing the consumption of cooling lubricants (CL), which cause damage to the environment and health as well as high costs. In order to maintain productivity and ensure the required component quality despite the reduction in coolant quantities, the use of coolant must be more targeted in the future. In particular, there is great potential in exploiting the tribological effect of the coolants. In order to utilize this in machining production, the underlying mechanisms of action must be understood in detail and taken into account in digital tools for process and tool development and their optimization.In the context of this follow up project in the framework of the priority project SPP 2231, developments for the improvement of friction modeling under consideration of a CL for numerical chip formation simulations will be performed for this purpose. This is achieved by coupling a microscopic tribology model with a macroscopic chip formation model and offers the possibility to model the friction in the chip formation zone as a function of temperature, relative speed, contact normal stress as well as surface topographies of the tribo-partners and an intermediate medium. In order to gain the technological understanding and the data for the modeling and to lay a basis for the later transfer to industrial production, additional basic investigations on the tribological behavior of the chip formation zone are planned. In the first phase of the project, experimental investigations of the working mechanisms of cooling lubricants were carried out and it has been succeeded to develop a micro-tribological model of the chip formation zone, which should make it possible to investigate these mechanisms on an experimentally inaccessible scale and make them usable for chip formation simulations. The micro-model is based on a fluid-structure contact simulation using spline-based finite element methods. In the next project phase, the coupling of the micro-tribological model with a chip formation model is planned. This coupling will allow to model the friction behavior in the numerical chip formation simulation locally graded considering a CL. To be able to achieve this goal, in-depth experimental investigations with the objectives of influence analysis and simulation validation are necessary. In addition to the application of a method for the visualization of the coolant distribution in the chip formation zone, these include in particular the characterization of the sticking and sliding zone as well as the determination of the local mechanical loads during machining. Finally, in preparation for the third funding phase, the experimental framework shall be transferred to a turning process.

在金属切割制造中，可以在减少冷却润滑剂（CL）的消耗时发现特别较大的可持续性潜力，这会损害环境和健康以及高成本。为了维持生产率并确保尽管量减少了冷却液的质量，但将来必须更具针对性的冷却液。特别是，利用冷却剂的摩擦学作用具有很大的潜力。为了将其用于加工生产，必须详细理解行动机制，并在数字工具中考虑过程和工具开发及其优化的数字工具。这是通过将微观摩擦学模型与宏观芯片形成模型耦合来实现的，并提供了模拟芯片形成区域中摩擦的可能性，该模型是温度，相对速度，接触正常应力以及底环党伴侣和中间介质的表面地形的函数的函数。为了获得技术理解和建模的数据并为以后转移到工业生产的基础，计划了有关芯片形成区摩擦学行为的其他基本研究。在项目的第一阶段中，进行了冷却润滑剂的工作机制的实验研究，并成功地开发了芯片形成区的微观图表模型，这应该可以使这些机制在实验性不可接受的尺度上研究这些机制，并使它们适用于CHIP形成模拟。微型模型基于使用基于样条的有限元方法的流体结构接触模拟。在下一个项目阶段，计划了微观图案模型与芯片形成模型的耦合。这种耦合将允许在考虑CL的本地分级的数值芯片形成模拟中对摩擦行为进行建模。为了能够实现这一目标，必须进行深入的实验研究，并具有影响分析和模拟验证的目标。除了应用方法以可视化芯片地层区域中冷却液分布的可视化外，这些方法尤其包括粘附区和滑动区的表征以及加工过程中局部机械载荷的确定。最后，在准备第三融资阶段，应将实验框架转移到转弯过程。