Modeling and Compensation of Thermic Processing Influence for Short Hole Drilling

在短孔钻削加工过程中，工件的升温对所制造部件的尺寸精度和表面质量都有很大影响。在六年的项目过程中，它是打算开发一个耦合的模拟工具，光滑粒子流体动力学（SPH）粒子方法和有限元方法（FEM）的基础上。使用该工具，可以模拟上述热效应以及短孔钻孔过程中所制造工件上的最终负载。本研究项目的主要目的是针对深孔钻削过程中由于热载荷引起的几何形状复杂的零件的变形制定仿真辅助补偿原则。基于本项目前两个阶段进行的仿真和实验研究所获得的结果，在第三个资助期，开发了一个针对短孔钻削过程的动态同步耦合SPH/FEM模型。在此基础上，对简单几何形状和复杂几何形状的零件进行了实验验证。这样，它的目的是创建一个适当的，热机械耦合的模拟工具，在第三个项目阶段，这将被用来找到补偿原则，最大限度地减少在加工过程中观察到的几何定义的切削刃的热影响。在为期两年的项目阶段以及整个研究项目即将结束时，基于模拟和实验研究验证了先前开发的短孔钻孔补偿措施。

Both the dimensional accuracy and the surface quality of a manufactured component are considerably influenced by the warming of the workpiece occurring during the machining process in short hole drilling. In the course of the six-year project, it is intended to develop a coupled simulation tool, based on the Smoothed Particle Hydrodynamics (SPH) particle method and the Finite Element Method (FEM). With this tool, it will be possible to model the aforementioned thermal effects as well as the resulting loads on the manufactured workpiece for the short hole drilling process. The main aim of this research project is to work out simulation-assisted compensation principles for the deformations of components with geometrically complex shapes arising due to thermal loads in short hole drilling.Based on the findings gained from the simulations and experimental investigations carried out during the first two phases of this project, a dynamically and synchronously coupled SPH/FEM model focusing on the short hole drilling process is developed in the third funding period. Following this, the process model worked out will be validated with the results of the experimental tests on components with geometrically simple as well as complex shape. That way, it is intended to create an adequate, thermomechanically coupled simulation tool in the third project phase, which will be used to find compensation principles minimizing the thermal influences observed during the process of machining with geometrically defined cutting edge. Towards the end of the two-year project phase and, thus, also of the overall research project, the previously developed compensatory measures for short hole drilling are validated based on simulations as well as experimental investigations.