Development of a process model for the simulation of adaptive control concepts for metal-cutting bandsawing

• Applicant: Dr.-Ing. Thomas Stehle
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: from 2016 to 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 289598126

Metal cutting with bandsaws is used in pre-machining for manifold tasks as a fast and efficient process. Nevertheless it becomes apparent that bandsawing causes high costs due to large cutting losses, a poor cutting quality and a short tool life. Within the framework of this project, the bandsaw blade tension influencing the bandsawing process will be examined to develop adaptive control concepts for improving cutting quality and tool life, which will increase the productivity of the overall process. For this reason, a virtual process model for bandsawing will be created, which allows simulating the influence of cutting parameters and machine-specific boundary conditions to accelerate the development of new adaptive control concepts for the bandsaw blade tension in bandsaws. At the beginning of this project, the bandsawing process will be analyzed by experimental investigations to determine the forces acting on the bandsaw blade and the machine as a whole. These examinations will be supported by extensive computer-aided FE simulations with ANSYS Workbench. The results of this research will be used to create the virtual process model with MATLAB/Simulink. In the second part of this project, different concepts for the adaptive control of the bandsaw blade tension in bandsaws will be developed. These concepts will be implemented in the virtual process model and analyzed regarding their control behavior. Finally, the adaptively controlled bandsaw blade tension in the bandsaw will be examined by experiment.

• DFG Programme: Research Grants
• Co-Investigator: Professor Dr.-Ing. Hans Christian Möhring