Efficient coolant lubricant application in narrow kerfs when sawing titanium alloys by simulation of thermal and mechanical fluid-solid interactions (Effi-Ti-Sim)

• Applicants: Professor Dr.-Ing. Stephan Kabelac; Professor Dr.-Ing. Hans Christian Möhring
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2020
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 439925537

The aim of this project is to increase the efficiency of circular sawing processes in titanium alloys with internal coolant lubricant supply using a holistic description in a simulation model. By using different machining conditions, an optimal effect of the coolant in terms of cooling and lubrication as well as chip formation and removal will be achieved. The first phase of the project focused on the experimental and simulative investigation of individual effects such as chip formation, heat transport mechanisms and fluid-solid interactions. The resulting analogous test setups were used in the second project phase to transfer simulation models of individual effects into coupled multiphysical simulation models. In the ABAQUS CEL model coupling approach, the chip formation simulation is extended by the thermo-fluid interactions with the help of the Nußelt correlations. In addition, a prototypical circular saw blade with an internal coolant supply has been realized. The third phase of the project is dedicated to the optimization of the circular sawing process using the developed models. Holistic experimental and simulative considerations are made in order to extend the models for two-tooth segments to multiple teeth in engagement. By investigating different chip space geometries and varying the number and positioning of the ICS channels, influences on chip formation and heat dissipation in the multi-tooth model are identified. Tool wear will be evaluated using a test setup for the targeted investigation of the multi-tooth model, taking into account different tool designs. The resulting knowledge and model-based descriptions will ultimately be combined in a holistic model that covers all relevant aspects of the circular sawing process.

• DFG Programme: Priority Programmes
• Subproject of: SPP 2231: Efficient cooling, lubrication and transportation – coupled mechanical and fluid-dynamical simulation methods for efficient production processes (FLUSIMPRO)
• Co-Investigator: Dr.-Ing. Thomas Stehle