Multi-scale modeling of the thermal workpiece load in the turning process considering the cutting fluid

考虑切削液的车削过程中工件热载荷的多尺度建模

• 批准号: 439919433
• 负责人: Professor Dr.-Ing. Thomas Bergs
• 金额: --
• 依托单位: Werkzeugmaschinenlabor - WZL
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 财政年份: 2020
• 资助国家: 德国
• 起止时间: 2019-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/439919433?language=en
• 关键词: Multi; scale; modeling; thermal; workpiece

The use of cutting fluid is beneficial in the machining technology in order to transport the process heat generated from the tool-workpiece interface and to reduce the frictional heat due to its lubricating effect. The thermo-mechanical load induced in this context has a considerable influence on the surface integrity and the associated functionality of the component. However, the thermal and mechanical load of the workpiece has been modeled separately in previous work. For a comprehensive understanding of the process, the investigation of the interaction between mechanical and thermal phenomena is necessary. Therefore, the main objective of the proposed research project is the multi-scale modeling of the thermal workpiece load in the turning process, considering the supply of cutting fluid and the tool wear condition. In the first funding period, a coupling approach between Computational Fluid Dynamics (CFD) and Finite Element Method (FEM) is developed. The coupling approach is based on the iterative exchange of mechanical and thermal parameters between FEM and CFD. Based on FEM simulations and experiments, the chip geometry is calculated and used as the input for CFD mesh generation. In the CFD simulation, the heat transfer coefficients are then quantified and transferred to the FEM simulation, which then calculates the modified chip geometry. In addition, further sub-models are developed and validated for the description of the friction behavior as well as the contact heat transfer under consideration of cutting fluid. Overall, this iterative coupling approach can be used to determine the temperature distribution and gradients in the boundary layer of complex components during machining. By enhancing the FEM chip formation simulation to the actual tribological conditions considering friction and heat transfer models, a major scientific gap in modeling approaches is closed, and thus a comprehensive virtual image of the machining process under real conditions can be achieved.

切割流体的使用在加工技术中是有益的，以运输从工件工作界面产生的过程热量，并由于其润滑作用而减少摩擦热量。在这种情况下诱导的热机械负荷对组件的表面完整性和相关功能具有很大影响。但是，工件的热负载和机械负载已在先前的工作中分别建模。为了全面了解该过程，必须研究机械现象和热现象之间的相互作用。因此，考虑到切割流体的供应和刀具磨损状况，提议的研究项目的主要目标是热量工件负载的多尺度建模。在第一个资金期间，开发了计算流体动力学（CFD）和有限元方法（FEM）之间的耦合方法。耦合方法基于FEM和CFD之间的机械和热参数的迭代交换。根据FEM模拟和实验，计算芯片几何形状并用作CFD网格生成的输入。在CFD模拟中，然后将传热系数定量并转移到FEM模拟中，然后计算了修饰的芯片几何形状。此外，开发并验证了进一步的子模型，以描述摩擦行为以及正在考虑切割液的接触传热。总体而言，这种迭代耦合方法可用于确定加工过程中复杂组件边界层的温度分布和梯度。通过考虑摩擦和传热模型的实际摩擦学条件，通过增强FEM芯片形成模拟，封闭了建模方法中的主要科学差距，因此可以实现实际条件下加工过程的全面虚拟图像。