A Coupling Approach Combining Computational Fluid Dynamics and Finite Element Method to Predict Cutting Fluid Effects on the Tool Temperature in Cutting Processes
A Coupling Approach Combining Computational Fluid Dynamics and Finite Element Method to Predict Cutting Fluid Effects on the Tool Temperature in Cutting Processes
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计算流体动力学与有限元方法相结合的耦合方法来预测切削液对切削过程中刀具温度的影响
DOI：
10.1115/1.4044102
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发表时间：
2019
期刊：
影响因子：
--
通讯作者：
Frekers
中科院分区：
文献类型：
--
作者：
Helmig;Ehrenpreis;Augspurger;Frekers
在金属切削加工中，切削液的使用可以降低刀具和工件上的热机械载荷，从而对工件表面质量产生显著影响。然而，为了模拟这些热机械过程，人们做了很多努力，但没有考虑切削液、刀具和工件之间的详细热传递。为了考虑换热效应，将计算流体力学(CFD)和有限元切屑形成模拟相结合，提出了一种耦合方法。在仿真之前，对两种不同材料(AISI1045和DA718)的干切削和湿切削条件下的正交切削进行了实验研究。为了测量干切削和湿切削条件下的刀具温度，将双色高温计放置在电火花加工(EDM)钻孔的刀具孔内。除了刀具温度，切削力在实验期间被记录下来，随后用于计算CFD模拟的热源项。实验完成后，进行了有限元切屑形成模拟，为CFD网格划分提供切屑形态。总体来说，CFD模拟结果与实验结果基本吻合，因为对于每个零件的设置，测量到的温度数据位于两种不同刀具几何形状的模拟结果之间。此外，数值计算和实验结果都表明，在湿式切削条件下，刀具温度降低，而在AISI 1045加工条件下，冷却效果更为显著。结果表明，钻孔的位置对刀具的局部温度分布有很大影响，因为钻孔等于热阻，从而导致刀具前端温度升高。
In metal cutting processes, the use of cutting fluids shows significant effects on workpiece surface quality by reducing thermomechanical loads on cutting tool and workpiece. Many efforts are made to model these thermomechanical processes, however without considering detailed heat transfer between cutting fluid, tool, and workpiece. To account for heat transfer effects, a coupling approach is developed, which combines computational fluid dynamics (CFD) and finite element method (FEM) chip formation simulation. Prior to the simulation, experimental investigations in orthogonal cutting in dry and wet cutting conditions with two different workpiece materials (AISI 1045 and DA 718) are conducted. To measure the tool temperature in dry as well as in wet cutting conditions, a two color pyrometer is placed inside an electrical discharge machining (EDM) drilled cutting tool hole. Besides tool temperature, the cutting force is recorded during the experiments and later used to calculate heat source terms for the CFD simulation. After the experiments, FEM chip formation simulations are performed and provide the chip forms for the CFD mesh generation. In general, CFD simulation and experiment are in reasonable agreement, as for each workpiece setup the measured temperature data are located between the simulation results from the two different tool geometries. Furthermore, numerical and experimental results both show a decrease of tool temperature in wet cutting conditions, however revealing a more significant cooling effect in a AISI 1045 workpiece setup. The results suggest that the placement of drilling holes has a major influence on the local tool temperature distribution, as the drilling hole equals a thermal resistance and hence leads to elevated temperatures at the tool front.
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