Project Details
Projekt
Simulation-based optimization of the milling process by regulating the tool temperature - knowledge transfer project (T14#)
Subject Area
Metal-Cutting and Abrasive Manufacturing Engineering
Term
since 2024
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 174223256
The goal of this transfer project is the integration of developed thermal and mechanical models and methods into a CAM software platform and to perform a prototype calculation of the tool temperature of a demonstration process. To achieve this goal, three project partners are working together with their specific expertise: The software company MODULEWORKS GmbH, the Machine Tool Laboratory WZL of RWTH Aachen University and the Chair of Heat and Mass Transfer WSA of RWTH Aachen University. MODULEWORKS GmbH, as an industrial partner and developer of CAM software solutions, will define the framework conditions and interfaces for model coupling and integrate the thermal and mechanical submodels into the overall model. The Chair of Heat and Mass Transfer will take over the modeling of all thermal phenomena, while the Machine Tool Laboratory will provide and further develop methods and models for the calculation of mechanical loads during the manufacturing process. The technological transfer starts with subdividing the calculated uncut chip thickens of the engagement simulation. The transient mechanical load and heat source distribution for each subdivided engagement area can be determined using the simulation already developed in the SFB. The overall thermomechanical load along the tool cutting edges can be obtained by superimposing the load of each individual engagement area. The scientific challenge lies not only in implementing the coupled simulation but also in meeting the requirements for geometry subdivision. Also for thermal modeling the developed methods in the SFB can be used. These include on the one hand the simulative and experimental determination of contact heat transfers at adjacent machine components and on the other hand the prediction of cooling lubricant induced convective heat transfers along the tool cutting edge. These methods will be used to generate a database for heat transfer coefficients, which will be accessed during the thermal simulation of the milling tool. In addition to the application of the SFB methods, the thermal model of the milling tool itself will also be extended as part of the transfer project. The extension includes in particular the integration of spatially and temporally resolved thermal boundary conditions in order to extend the accuracy level and validity range of the cutter model. Based on the findings of the transfer project, the process control can be extended in the future. The current state of the art involves the control of milling processes based on occurring process forces. Temperature limits can only be avoided with large dimensioned safety factors. By incorporating the methods developed in the SFB, future control strategies can also take temperature into account as an integral variable of the manufacturing process and explicitly include temperature limits.
DFG Programme
CRC/Transregios (Transfer Project)
Applicant Institution
Technische Universität Dresden
Project Heads
Professor Dr.-Ing. Thomas Bergs; Professor Dr.-Ing. Reinhold Kneer
