Development of a simulative model for analysis of the effect of cooling lubricants in deep hole drilling with small diameters with respect to chip formation

开发小直径深孔钻削中冷却润滑剂对切屑形成影响的模拟模型

• 批准号: 317373968
• 负责人: Professor Dr.-Ing. Dirk Biermann
• 金额: --
• 依托单位: Institut für Spanende Fertigung
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2016
• 资助国家: 德国
• 起止时间: 2015-12-31 至 2022-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/317373968?language=en
• 关键词: Development; simulative; model; analysis; effect

In the previous DFG project, a fluid-structure interaction (FSI) simulation model was developed to analyze the influence of the cooling lubricant during spiral deep hole drilling. It was possible, to model the interaction between tool, workpiece and chip formation by coupling the Finite Element (FE) and Computational Fluid Dynamics (CFD) simulation. Instead of water, deep hole drilling oil with a specified, temperature dependent kinematic center viscosity was used for the first time in the CFD simulation. However, the temperature changes that occur during the machin-ing process depending on the material to be machined and the machining time were not taken into account for the viscosity of the oil in the CFD simulation of the coolant flow. In order to apply the FSI simulation model to optimize tools and processes, it is necessary to consider in detail the cool-ing lubricant viscous properties, which are strongly dependent on temperature and pressure. The objective in the focus of this follow-up project is therefore to extend the existing FSI simulation model accordingly, in order to include the changing properties of the coolant due to pressure and temperature changes in the machining process. Using mathematical equations, the dynamic cool-ing lubricant properties, can be defined and implemented by corresponding variables in the FSI simulation model. Deep hole drilling experiments using spiral deep hole drills and the workpiece ma-terial Ti-6Al-4V provide the input data for the simulation. After determining the tool temperature with the simulation for different feeds and cutting speeds, a numerical calculation of the fluid flow at dif-ferent cooling lubricant pressures is performed. The aim is to maximize the coolant flow velocity and the coolant flow pressure in order to provide a better coolant supply in the cutting edge area. With these simulatively determined parameter combinations, experimental tool life investigations will be carried out to determine the influence of the improved coolant supply on tool wear.

在先前的DFG项目中，开发了流体结构相互作用（FSI）模拟模型，以分析螺旋深孔钻孔过程中冷却润滑剂的影响。通过耦合有限元（Fe）和计算流体动力学（CFD）模拟，可以建模工具，工件和芯片形成之间的相互作用。在CFD模拟中，首次使用了带有指定温度的运动学中心粘度的深孔钻孔的深孔钻孔。但是，根据要加工的材料的不同，在机械过程中发生的温度变化并未考虑到冷却液流量的CFD模拟中油的粘度。为了应用FSI仿真模型来优化工具和过程，有必要详细考虑凉爽润滑剂粘性特性，该特性在很大程度上取决于温度和压力。因此，该后续项目的重点的目的是相应地扩展现有的FSI仿真模型，以包括加工过程中压力和温度变化导致冷却液的变化性能。使用数学方程，可以通过FSI仿真模型中的相应变量来定义和实现动态冷润滑剂性能。深孔钻孔实验使用螺旋深孔钻和工件MA-Perial Ti-6Al-4V提供了模拟的输入数据。通过模拟不同进料和切割速度确定刀具温度后，进行了在不同的冷却润滑压力下对流体流量进行的数值计算。目的是最大化冷却液流量速度和冷却液流动压力，以便在尖端区域提供更好的冷却液供应。通过这些模拟确定的参数组合，将进行实验性工具寿命调查，以确定改进的冷却液供应对工具磨损的影响。