Modelling of the coolant lubrication distribution during single-lip deep hole drilling under consideration of the chip transport by means of CFD and SPH/DEM simulations for tool and process optimization

通过 CFD 和 SPH/DEM 模拟，在考虑切屑传输的情况下，对单唇深孔钻削期间的冷却剂润滑分布进行建模，以实现刀具和工艺优化

• 批准号: 405605200
• 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
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/405605200?language=en
• 关键词: Modelling; coolant; lubrication; distribution; during

In the continuation of the successful first phase of the DFG project entitled: "Modelling of the coolant lubrication distribution during single-lip deep hole drilling under consideration of the chip transport by means of CFD and SPH/DEM simulations for tool and process optimization", the focus will be on further optimization of the single-lip drill and extensions to the developed simulation model. In the first phase, it was shown that the geometry of the cooling channel has a significant influence on the transient chip removal and that this yields a fundamental potential for optimization. Since the possibilities to modify a micro single-lip drill are limited due to its small size, a single-lip drill with a larger diameter and two cooling channels is considered instead in the second phase. Based on the developed SPH/DEM/CFD modelling approach, a geometric optimization of the cross-sectional area and the position of the internal cooling channels, the insertion of a drainage groove and the improvement of the oil chamber clearance angle will be carried out. Extending the simulation model, the friction conditions during transient chip removal are to be taken into account. In the case of the single-lip drill, the chips flow out of the bore hole with the cooling lubricant along the chip groove under undisturbed conditions without major contact with the drill and the borehole wall. However, if repeated collisions of the chips with the borehole wall occur, case friction modelling plays an important role. Furthermore, flexible modelling of the chips will improve the simulation quality in order to gain new insights into chip transport under these non-optimal conditions, which in the worst case can lead to a jamming of the drill.

在DFG项目成功的第一阶段的延续中，题为：“通过CFD和SPH/DEM模拟工具和工艺优化，在考虑切屑传输的情况下，对单唇深孔钻削过程中的冷却剂润滑分布进行建模”，重点将是进一步优化单唇钻头和扩展已开发的模拟模型。在第一阶段中，它被证明是冷却通道的几何形状上的瞬态切屑去除有显着的影响，这产生了优化的基本潜力。由于微型单唇钻的尺寸小，修改的可能性受到限制，因此在第二阶段考虑使用具有较大直径和两个冷却通道的单唇钻。基于开发的SPH/DEM/CFD建模方法，将对内部冷却通道的横截面积和位置进行几何优化，插入排水槽并改善油室间隙角。扩展了仿真模型，考虑了瞬时排屑过程中的摩擦条件。在单刃钻头的情况下，切屑在不受干扰的条件下与冷却润滑剂一起沿着切屑槽流出钻孔，而不与钻头和钻孔壁主要接触。然而，如果发生碎屑与井壁的反复碰撞，则套管摩擦建模起着重要作用。此外，灵活的切屑建模将提高仿真质量，以便在这些非最佳条件下获得对切屑输送的新见解，在最坏的情况下，这可能导致钻头卡住。