Modeling and Compensation of Thermic Processing Influence for Short Hole Drilling

在短孔钻孔加工过程中，工件的升温对零件的尺寸精度和表面质量都有很大的影响。在这个为期六年的项目中，它打算开发一个基于光滑粒子流体动力学（SPH）粒子方法和有限元方法（FEM）的耦合模拟工具。有了这个工具，就可以模拟前面提到的热效应，以及在短孔钻孔过程中对制造工件产生的载荷。本课题的主要目的是研究具有复杂几何形状的零件在短孔钻削过程中由于热载荷而产生的变形的仿真辅助补偿原理。基于该项目前两个阶段的模拟和实验研究结果，在第三个资助阶段建立了一个专注于短孔钻井过程的动态同步耦合SPH/FEM模型。在此基础上，通过对几何形状简单和复杂的零件进行实验测试，验证所建立的工艺模型。这样，它的目的是在第三个项目阶段创建一个适当的，热机械耦合模拟工具，它将用于寻找补偿原则，最大限度地减少在几何定义切削刃加工过程中观察到的热影响。在为期两年的项目阶段结束时，以及整个研究项目结束时，基于模拟和实验调查，对先前开发的短孔钻井补偿措施进行了验证。

Both the dimensional accuracy and the surface quality of a manufactured component are considerably influenced by the warming of the workpiece occurring during the machining process in short hole drilling. In the course of the six-year project, it is intended to develop a coupled simulation tool, based on the Smoothed Particle Hydrodynamics (SPH) particle method and the Finite Element Method (FEM). With this tool, it will be possible to model the aforementioned thermal effects as well as the resulting loads on the manufactured workpiece for the short hole drilling process. The main aim of this research project is to work out simulation-assisted compensation principles for the deformations of components with geometrically complex shapes arising due to thermal loads in short hole drilling.Based on the findings gained from the simulations and experimental investigations carried out during the first two phases of this project, a dynamically and synchronously coupled SPH/FEM model focusing on the short hole drilling process is developed in the third funding period. Following this, the process model worked out will be validated with the results of the experimental tests on components with geometrically simple as well as complex shape. That way, it is intended to create an adequate, thermomechanically coupled simulation tool in the third project phase, which will be used to find compensation principles minimizing the thermal influences observed during the process of machining with geometrically defined cutting edge. Towards the end of the two-year project phase and, thus, also of the overall research project, the previously developed compensatory measures for short hole drilling are validated based on simulations as well as experimental investigations.