Efficient coolant lubricant application in narrow kerfs when sawing titanium alloys by simulation of thermal and mechanical fluid-solid interactions (Effi-Ti-Sim)

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The aim of this project is to develop a simulation model to calculate an efficiency-optimized design of the circular sawing of titanium alloys in advance. This model has to provide the lowest possible KSS pressure and volume flow for which an optimal cooling effect, tribology and chip transport in the cutting gap for different machining conditions is achieved. In the first phase of the project, fundamental experimental and simulative investigations of mechanisms in the sawing process were carried out. The model approaches, on which the desired simulation model is based, must be rooted on a comprehensive understanding of highly dynamic chip formation, heat transport mechanisms and fluid mechanics including the coupled fluid-solid interactionsIn the second phase of the project, the separate models for chip formation, the multi-phase flow and the heat transfer in the chip space, which were developed under partially idealized conditions, are to be consolidated, parameterized and merged. The consolidation and parameterization take place via further experiments with the realized and validated test setups. The sub-models are combined using the CEL approach in ABAQUS on the one hand and by coupling ABAQUS and the CFD software OpenFOAM or FLUENT on the other. An intensive exchange with other sub-projects within the SPP is planned for both areas of responsibility.To expand the parameter field, the test rigs are operated at increased surface temperatures, so that in addition to convective vapour-liquid interactions, radiation influences can also be taken into account. The two test rigs for heat transfer, which have already provided initial results at moderate temperatures, are also intended for the further characterization of particle-laden flows in the chip space with simultaneous evaporation of the KSS.