Energy-efficient high-performance deep hole drilling using twist drills

干切削和最小量润滑（MQL）具有降低加工过程能耗的潜力。在金属加工中消除冷却润滑剂可以产生各种环境和经济效益，但它也增加了对切削技术的要求。在许多情况下，深孔加工是引入干式和MQL技术的排除标准。由工件内切削区引起的高热量输入，特别是在长径比高的情况下具有挑战性的排屑是深孔钻削中的两个问题，这可能导致工艺可靠性不足，因此决定不引入干式加工或MQL。基于对MQL下铝铸件深孔钻削的基础研究，在该知识转移项目中，不同的解决方案被转移到新的应用中并进行优化。其主要目标是实现高能效高性能MQL深孔钻削，用于钢制成的复杂部件，钢仍然是最重要的结构材料之一。来自Münsingen的HPM Technology致力于MQL技术，并开发了一种新的MQL混合喷嘴和设备以及新的冷却策略。因此，必须通过创新的流体来增强低冷却效果，而不会降低普通MQL的良好润滑能力。来自Altenstadt的第二个项目合作伙伴米勒专门为MQL下的应用开发了长径比高达l/D = 60的高性能麻花钻。ISF的工艺流程开发与一种基于仿真的直线度偏差补偿创新方法有关，直线度偏差通常是深孔钻削操作中的关键质量特征。通过与工业合作伙伴的密切合作，我们可以对要求苛刻的深孔钻削工艺和相应部件进行全面而详细的分析。所开发的解决方案将提升当前的技术水平，并在节能MQL下实现高性能深孔钻削的广泛工业应用。为了消除现有的障碍，有关MQL的发展进行了验证复杂的演示部分。

Dry cutting and minimum quantity lubrication (MQL) have the potential to reduce the energy consumption of machining processes. The elimination of cooling lubricant in metalworking can generate various environmental and economic benefits, but it also increases the requirements with regard to the cutting technology. In many cases, the machining of deep holes is an exclusion criterion for the introduction of dry and MQL techniques. The high heat input, caused by the inner cutting zone within the workpiece, and particularly the challenging chip evacuation in case of high length-to-diameter ratios are two problems in deep hole drilling, which can originate insufficient process reliability and thus a decision against the introduction of dry machining or MQL. Based on the fundamental investigations in deep hole drilling of aluminium casting under MQL, different solutions are transferred to new applications and optimized in this knowledge transfer project. The main objective is to enable the energy-efficient high-performance MQL deep hole drilling for complex components made of steel, which is still one of the most important structural materials. HPM Technology from Münsingen works on the MQL technique and develops a new MQL mixing nozzle plus device as well as new cooling strategies. Thereby the low cooling effect has to be enhanced by innovative fluids without reducing the good lubrication capability of common MQL. High-performance twist drills with a length-to-diameter ratio of up to l/D = 60 are developed particularly for the application under MQL by the second project partner Miller from Altenstadt. The technological process development at the ISF is linked to an innovative method for simulation-based compensation of the resulting straightness deviation, which is often a critical quality feature in deep hole drilling operations. The close collaboration with the industrial partners allows both, holistic and detailed analysis of the demanding deep hole drilling process and the corresponding components. The developed solutions should enhance the current state of the art and enable wide industrial application of the high-performance deep hole drilling under energy-efficient MQL. To eliminate the existing obstacles regarding the MQL, the developments are validated on complex demonstrator parts.