Modelling of the cooling effect in tool grinding under consideration of process-related uncertainties

磨削加工在几何形状加工的整体硬质合金刀具生产工艺链中起着核心作用。它定义了工件的几何形状，影响基材性能，并导致高达60%的刀具生产成本。切削条件对最终工件质量的影响已经在许多研究项目中进行了研究，而接触区冷却润滑剂的流体动力学过程及其对工件热负荷的影响在很大程度上仍然未知。为了缩小这一知识差距，该项目的目的是研究刀具磨削的多尺度材料去除流体模拟，考虑到过程相关的不确定性。目标是基于这样一个假设，即磨削过程中的微观（如砂轮形貌、冷却润滑剂的物理性质）和宏观（如切削条件）效应的结合会显著影响过程中冷却和润滑的有效性。相互作用的一般知识及其模拟构成了以更高生产率进行无损伤加工的基础。同时，假定微观过程存在不可预测的偏差，在模拟中必须以不确定性的形式加以考虑。一个特别的重点是对冷却润滑剂分布和由此产生的工件热负荷的模糊计算。有了这个目标，该项目解决了有关多尺度问题的模拟，冷却润滑剂的传热建模和相应的热传输的问题。此外，还考虑了生产过程中的不确定性。所研究的方法具有基本特征，因此可以与优先方案2231的其他项目合作转移到其他应用中。

The grinding process plays a central role in the process chain for the production of solid carbide tools for geometrically determined machining. It defines the geometric shape of the workpiece, influences the substrate properties and causes up to 60 % of the costs in tool production. The influence of the cutting conditions on the resulting workpiece quality has already been investigated in numerous research projects, while fluid dynamic processes of the cooling lubricant in the contact zone and their effects on the thermal load of the workpiece are still largely unknown. In order to close this knowledge gap, the aim of the project is to investigate a multi-scale material removal fluid simulation for tool grinding, taking into account process-related uncertainties. The objective is based on the hypothesis that the combination of micro- (e.g. grinding wheel topography, physical properties of the cooling lubricant) and macroscopic (e.g. cutting conditions) effects during grinding significantly influence the effectiveness of cooling and lubrication in the process. The general knowledge of the interactions and their simulation form the basis for damage-free processing at higher productivity. At the same time, it is assumed that the microscopic processes are subject to unpredictable deviations, which must be taken into account in form of uncertainties in the simulation. A special focus is on the fuzzy calculation of the cooling lubricant distribution and the resulting thermal load on the workpiece. With this objective, the project addresses questions concerning the simulation of multi-scale problems, the modelling of the heat transfer into the cooling lubricant and the corresponding heat transport. In addition, the consideration of uncertainties in production processes is addressed. The methods to be researched have a fundamental character and can therefore be transferred to other applications in cooperation with other projects of the priority program 2231.