Deep hole drilling using senor integrated tools to adjust defined functional characteristics into the near-surface peripheral zone

使用传感器集成工具进行深孔钻削，将定义的功能特性调整到近地表外围区域

• 批准号: 401792429
• 负责人: Professor Dr.-Ing. Hans Christian Möhring
• 金额: --
• 依托单位: MPA Stuttgart, Otto-Graf-Institut (FMPA)
• 依托单位国家: 德国
• 项目类别: Priority Programmes
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/401792429?language=en
• 关键词: Deep; hole; drilling; using; senor

Deep holes in components being exposed to highly alternating pressure loads (e.g. injection components in large diesel engines) are subject to high demands on the near-surface peripheral zone properties. Microcrack formation in the bore wall must be avoided during machining, as these can lead to component failure. This is caused by surface defects or unfavorable residual stress conditions. High surface quality can be achieved by using the single-lip deep drilling method, but residual compressive stresses must be induced by subsequent machining processes (e.g. autofrettage). This is associated with additional machining effort as well as low flexibility in responding to transient conditions of previous deep drilling processes.The projects main object is the metrological detection of process changes and their compensation by means of in-process-capable control approaches. In the first project phase a sensor-integrated single-lip drilling tool for in-process detection of the thermo-mechanical state, a combined numerical-analytical compensation model of the machining temperature, machining and material models were developed and validated. Also a process controller was conceptualized. Machining tests were performed on the heat-treated steel 42CrMo4 (ASTM A331).The follow-on project is based on the results of the first funding phase and aims to develop a robust controller based on a soft sensor, with which the near-surface zone properties of deep holes can be specifically adjusted. The following sub-goals are pursued here: A detailed understanding of the mechanisms in the near-surface microstructure (crystal plasticity), on dislocation dynamics and on separation processes at the atomistic level in the material. Merge of models created in the first funding phase on the correlation between near-surface zone properties and machining parameters. Control strategies for the targeted influencing of the near-surface zone in a controller environment in which material- and requirement-dependent (not time-critical) and process-dependent boundary conditions (time-critical) are combined and brought together within a controller architecture. Concepts of a soft- and hardware-based in-process control for deep hole drilling, where input variables of the controller are the tool acceleration and temperature at the effective point (by means of sensor-integrated tool and compensation model taken from the first project phase) as well as the mechanical load (forces, moment via dynamometer). The control variables are the rotational speed and the feed rate of the single-lip drill. Based on the input and output variables as well as the time relevance of the output variables, a suitable controller concept is available, which divides the tasks of the controller into time-critical and -uncritical fields. The controller is connected to the machine control system. Controller and control strategies are validated on the basis of application scenarios.

暴露于高交变压力载荷的部件（例如大型柴油发动机中的喷射部件）中的深孔对近表面外围区域特性有很高的要求。在加工过程中必须避免孔壁中形成微裂纹，因为这些微裂纹会导致部件失效。这是由表面缺陷或不利的残余应力条件引起的。高表面质量可以通过使用单唇深钻孔方法来实现，但是残余压应力必须通过后续的加工工艺（例如自增强）来诱导。这与额外的加工工作量以及对先前深孔加工过程的瞬态条件的低灵活性有关。该项目的主要目标是通过过程中的控制方法对过程变化进行快速检测和补偿。在第一个项目阶段，开发并验证了用于热机械状态的过程检测的传感器集成式单唇钻削工具、加工温度的组合数值分析补偿模型、加工模型和材料模型。还提出了过程控制器的概念。在热处理钢42CrMo4（ASTM A331）上进行了加工试验。后续项目是基于第一阶段资助的结果，旨在开发一种基于软传感器的鲁棒控制器，可以专门调整深孔的近表面区域特性。在这里追求以下子目标：详细了解近表面微观结构（晶体塑性），位错动力学和分离过程中的原子级材料的机制。合并第一个融资阶段创建的模型，以了解近表面区域属性与加工参数之间的相关性。在控制器环境中，材料和要求相关（非时间关键）和过程相关边界条件（时间关键）相结合，并在控制器架构中汇集在一起，有针对性地影响近表面区域的控制策略。基于软件和硬件的深孔钻削过程控制的概念，其中控制器的输入变量是有效点的刀具加速度和温度（通过传感器集成刀具和第一项目阶段的补偿模型）以及机械负载（通过测力计的力和力矩）。控制变量为单刃钻头的转速和进给速率。基于输入和输出变量以及输出变量的时间相关性，一个合适的控制器的概念是可用的，它将控制器的任务分为时间关键和非关键字段。控制器连接到机器控制系统。在应用场景的基础上对控制器和控制策略进行了验证。