Experimental and model-based basic investigations on contact mechanical load distribution and the resulting production quality for wet grinding

基于实验和模型的接触机械载荷分布和湿磨生产质量的基础研究

• 批准号: 498570013
• 负责人: Professor Dr.-Ing. Christoph Herrmann
• 金额: --
• 依托单位: Institut für Werkzeugmaschinen und Fertigungstechnik
• 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/498570013?language=en
• 关键词: Experimental; model; based; basic; investigations

The grinding of metals typically generates high amounts of heat which must be transported out of the contact zone by a cutting fluid to avoid excessive workpiece temperatures and subsequently workpiece damages. In addition to cooling, the main tasks of the cutting fluid include lubricating the contact zone and removing the chips. The fulfilment of these functions is strongly dependent on the properties of the coolant lubricant and the type of its feed. An understanding of these process-structure-property relationships is of particular interest regarding the quality of the grinding process and a resource efficient use of cutting fluids. An assessment of the use of coolant lubricants with regard to the functions is usually carried out experimentally and only rarely or limited to models or simulations. In a first step, usually various test methods such as the Reichert-Test are used at the laboratory scale for the experimental investigation of the lubricating effect of fluids. However, these investigations only correspond to the real grinding conditions to a very limited extent and must therefore be supplemented by complex investigations at machine level. The existing numerical methods for the description of grinding processes usually consider either the single grit cutting during grinding or the hydrodynamics caused by the cutting fluid supply, a consideration of both factors is not known. Based on the identified research gap, the current project will investigate the influence of cooling lubricants on wet grinding processes. In interdisciplinary cooperation between production technology and simulation tools, the mechanisms which determine the close interactions of surface contours, hydrodynamics, force transmission, workpiece and tool topographies, material removal, heat generation and heat transfer will be investigated. Special attention is paid to the gap topographies, which change dynamically with the grinding process. The basis of the modelling strategy used here is a mathematical model based on the Reynolds equation, which is very flexible to possible extensions. Within the scope of the project, a close connection between experiments with innovative test equipment and models on different scales will be ensured. On the one hand, the studies on a modified Reichert-Test in combination with a model on the roughness level will be combined to characterize the processes on the microscopic scale. On the other hand, the hydrodynamic influence will be investigated both experimentally and by modelling. Finally, the knowledge is transferred to the machine level. The project represents a first essential step towards a holistic understanding of the influence of cutting fluids on the effectiveness of the wet grinding process. The models developed in this project will build the basis for further studies that will allow the implementation of optimization strategies for cutting fluids in the future.

金属的磨削通常会产生大量的热量，这些热量必须通过切削液从接触区传送出去，以避免过高的工件温度和随后的工件损坏。除了冷却之外，切削液的主要任务还包括润滑接触区和去除切屑。这些功能的实现在很大程度上取决于冷却剂润滑剂的性质及其进料的类型。了解这些过程-结构-性能关系对于磨削过程的质量和切削液的资源有效利用具有特别重要的意义。冷却剂润滑剂的使用与功能相关的评估通常通过实验进行，很少或仅限于模型或模拟。在第一步中，通常在实验室规模下使用各种测试方法，例如Reichert测试，用于流体润滑效果的实验研究。然而，这些研究仅在非常有限的程度上对应于真实的磨削条件，因此必须通过机器水平的复杂研究来补充。现有的磨削过程的数值模拟方法通常考虑磨削过程中的单磨粒切削或切削液供给引起的流体动力学，这两个因素的考虑是未知的。基于已确定的研究差距，本项目将研究冷却润滑剂对湿磨过程的影响。在生产技术和模拟工具之间的跨学科合作中，将研究确定表面轮廓，流体动力学，力传递，工件和工具形貌，材料去除，发热和传热之间密切相互作用的机制。特别注意的是差距形貌，动态变化的磨削过程。这里使用的建模策略的基础是基于雷诺方程的数学模型，该模型非常灵活，可以进行扩展。在该项目范围内，将确保在不同规模的创新测试设备和模型的实验之间建立密切联系。一方面，结合粗糙度模型的改进的Reichert检验的研究将被结合起来，以表征微观尺度上的过程。另一方面，将通过实验和建模来研究流体动力学的影响。 最后，知识被转移到机器层面。该项目是全面了解切削液对湿磨工艺有效性影响的第一个重要步骤。该项目中开发的模型将为进一步的研究奠定基础，以便在未来实施切削液的优化策略。