Tool and Process Optimization for efficient Ejector Deep-Hole Drilling-Processes using Smoothed Particle Hydrodynamics (SPH)

使用平滑粒子流体动力学 (SPH) 优化工具和工艺，实现高效喷射器深孔钻削工艺

• 批准号: 439917965
• 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: Priority Programmes
• 资助国家: 德国
• 项目状态: 未结题
• 来源: https://gepris.dfg.de/gepris/projekt/439917965?language=en
• 关键词: Tool; Process; Optimization; efficient; Ejector

Ejector deep hole drilling allows to exploit the process-typical advantages of deep hole drilling, such as high metal removal rates as well as low straightness deviations, on conventional machining centers for industrial applications at relatively low cost, because no expensive special machines with complex sealing for the cooling lubricant supply are required for the process. Another advantages of ejector deep hole drilling lie in the excellent surface qualities and bore quality that can be achieved compared to conventional drilling methods. The guide pads on the drill head generate a smoothing of the roughness peaks on the bore surface by plastic deformation of the bore wall, so that typically no reworking of the bores, e.g. by reaming, is required. In addition, the removal of chips through the inner tube of the tool prevents damage to the bore wall produced. Ejector deep hole drilling offers great potential for making the use of cooling lubricant (coolant) more energy- and resource-efficient with regard to the main functions of cooling, lubricating, and transporting chips, thus contributing to an increase in efficiency and a shortening of the process chain in production. In the first stage of the research project, the grid-free simulation approach of Smoothed Particle Hydrodynamics (SPH) in combination with current experimental and measurement analysis methods was used to develop an in-depth understanding of the interactions of the flow conditions and to implement it in a physical simulation model. The results of the successful interdisciplinary collaboration of the research institutes have already been published in various scientific publications. An essential goal of the second phase of this project is to extend the simulation model by a parallel Incompressible Smoothed Particle Hydrodynamics (ISPH) algorithm in order to realize a coupling with the thermal tool and workpiece loads. With the aid of the simulation model and a static load analysis based on the tool load determined experimentally during the drilling process, the design of the drill head is adapted to allow an improved coolant supply to the cutting edge and the occurrence of the ejector effect at lower coolant volume flows, as well as to improve chip removal. Finally, the flow-optimized ejector tools are additively manufactured and used.

顶出式深孔钻削允许以相对低的成本在用于工业应用的常规加工中心上利用深孔钻削的工艺典型优势，例如高金属去除率以及低直线度偏差，因为该工艺不需要具有用于冷却润滑剂供应的复杂密封的昂贵的专用机器。喷射器深孔钻削的另一个优点在于与传统钻削方法相比可以实现出色的表面质量和孔质量。钻头上的导向垫通过孔壁的塑性变形使孔表面上的粗糙度峰平滑，使得通常不需要例如通过铰孔对孔进行再加工。此外，通过工具的内管去除切屑防止对所产生的孔壁的损坏。喷射式深孔钻在冷却润滑剂（冷却液）的使用方面具有很大的潜力，在冷却、润滑和输送切屑的主要功能方面具有更高的能源和资源效率，从而有助于提高效率和缩短生产过程链。在研究项目的第一阶段，光滑粒子流体动力学（SPH）的无网格模拟方法与当前的实验和测量分析方法相结合，用于深入了解流动条件的相互作用，并在物理模拟模型中实施。各研究机构成功开展跨学科合作的成果已在各种科学出版物上发表。该项目第二阶段的一个基本目标是通过并行不可压缩光滑粒子流体动力学（ISPH）算法扩展仿真模型，以实现与热工具和工件负载的耦合。借助仿真模型和基于钻孔过程中实验确定的刀具载荷的静态载荷分析，钻头的设计适合于改善对切削刃的冷却剂供应以及在较低冷却剂体积流量下发生喷射器效应，以及改善切屑去除。最后，增材制造和使用流动优化的喷射器工具。