Compensation of Shape and Dimensional Deviations Due to Thermo-Elastic Deformation During Dry Machining

干式加工过程中热弹性变形引起的形状和尺寸偏差的补偿

• 批准号: 426824785
• 负责人: Professor Dr.-Ing. Thomas Bergs
• 金额: --
• 依托单位: Werkzeugmaschinenlabor - WZL
• 依托单位国家: 德国
• 项目类别: Research Grants (Transfer Project)
• 财政年份: 2019
• 资助国家: 德国
• 起止时间: 2018-12-31 至 2020-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/426824785?language=en
• 关键词: Compensation; Shape; Dimensional; Deviations; Due

In conjunction with the further development of cutting materials in manufacturing technology, it is now possible in many applications to completely dispense with cooling lubrication of the cutting tool or to use only minimum quantity lubrication. In this way, it is feasible to save costs for the provision, maintenance and disposal of various cooling lubricants.The elimination of cooling lubricants during dry machining, however, causes a change in the process heat generated and its distribution within the thermodynamic system, consisting of tool, workpiece, chips and the machine tool environment. The occurring heat flows cause a deformation of the workpiece and an undesired displacement of the machine components. This results directly in deviations in shape and dimension of the manufactured workpieces, which is why process design is much more complex than using conventional cooling lubrication. Due to the temporal and spatial complexity of the physical process involved, the deformations that occur cannot yet be compensated by simple analytical calculations or empirical knowledge.The overriding goal of the transfer project is therefore to implement the compensation of thermo-elastic deformations on the basis of a real application case for the first time and thus to transfer it into industrial practice. For this, it is necessary to extend already developed methods by the thermo-elastic displacement of the tool. Subsequently, strategies for the compensation of such misalignments and deformations can be derived, which enable dry hard turning of complex components with high demands on shape and dimensional accuracy.The multi-scale procedure developed in the DFG research project "Development of a model for the calculation and compensation of thermo-elastic shape and dimensional errors during dry machining" enables the heat flows in the equilibrium state of a turning process to be calculated on a mesoscopic scale by means of a chip formation simulation and to be transferred to a macroscopic component model for the calculation of heating and ultimately thermo-elastic deformation. In the basic research project of the SPP 1480, the suitability of this approach for the precise and time-efficient calculation of the thermo-elastic deformations of a workpiece could be proven. This calculation forms the basis for deriving a compensation strategy to avoid dimensional and shape errors.

结合制造技术中切割材料的进一步开发，现在在许多应用中可以完全分配切割工具的冷却润滑或仅使用最小润滑。通过这种方式，可以节省各种冷却润滑剂的提供，维护和处置成本。但是，在干加工过程中消除冷却润滑剂，导致过程热量的变化及其在热力学系统中的分布，包括工具，工件，工具，芯片和机械工具工具环境。发生的热量流引起工件的变形和机器组件不需要的位移。这直接导致制造工件的形状和尺寸偏差，这就是为什么过程设计比使用常规冷却润滑更为复杂的原因。由于所涉及的物理过程的时间和空间复杂性，因此发生的变形尚不能通过简单的分析计算或经验知识来补偿。因此，转移项目的覆盖目标是在第一次实现实际应用案例的基础上实施热弹性变形的补偿，从而将其转移到工业实践中。为此，有必要通过工具的热弹性位移扩展已经开发的方法。随后，可以得出赔偿此类未对准和变形的策略，这可以使DFG研究项目中开发的多尺度过程对复杂的组件进行干燥的硬转转。在介质尺度上，通过芯片形成模拟，并将其转移到宏观成分模型中，以计算加热和最终的热弹性变形。在SPP 1480的基础研究项目中，可以证明这种方法对工件的热弹性变形的精确和及时计算的适用性可以证明。该计算构成了避免维数和塑造错误的补偿策略的基础。