Simulative analysis of the influence of cutting fluids on the machining process

切削液在加工过程中的主要作用是冷却刀具、工件和机床部件，润滑工件与刀具材料之间的接触面，以及支持切屑去除。切削液的应用往往通过减少热机械刀具载荷来显著延缓刀具磨损的演变。为了经济和环保地使用切削液，必须对所有工艺参数进行精确设置。了解工艺参数和所产生的刀具载荷之间的关系对于实现这一目的至关重要。然而，它们的实验测定是非常困难的，例如切削液阻碍了测量系统的使用。数值模拟是为这一任务而定的，但到目前为止，只能确定没有切削液的加工过程的热机械载荷。没有允许对切屑形成过程和切屑形成区中的切削液流动进行热耦合计算的模拟系统。为了准确地分析切削液对加工过程的影响，并支持刀具和工艺的发展，需要这样的模型。因此，本研究项目的目的是对切削液的车削过程进行仿真分析。冷却和润滑策略，传统的溢流冷却和最小数量的润滑(MQL)将被研究。为此，将开发一个软件工具，允许模拟切削液对热机械刀具载荷的影响以及切屑形成过程。有限点集方法将被用作模拟方法，因为它的无网格方法为自由曲面的映射提供了所需的灵活性。

The main functions of cutting fluids in machining processes are the cooling of the cutting tool, the workpiece and the machine tool components, the lubrication of the contact surfaces between workpiece and cutting material as well as the support of the chip removal. The application of a cutting fluid often leads to a significant retardation of the tool wear evolution by the reduction of thermo-mechanical tool loads. For the economical and ecological use of cutting fluids a precise set-up of all process parameters is necessary. The knowledge about the relationships between the process parameters and the resulting tool loads are essential for this purpose. However, their experimental determination is very difficult as e.g. the cutting fluid impedes the use of measurement systems. The numerical cutting simulation is predestined for such a task, but the thermo-mechanical loads can only be determined for machining processes without cutting fluids up to now. There is no simulation system which allows the thermally coupled calculation of the chip formation process and the flow of the cutting fluid in the chip formation zone. Such a model is required in order to accurately analyze the influence of the cutting fluid on the machining process and to support tool and process developments. Therefore, the aim of this research project is the simulative analysis of turning processes with cutting fluids. The cooling and lubrication strategies conventional flood cooling and minimum quantity lubrication (MQL) will be investigated. For this purpose, a software tool will be developed which allows the simulation of the influence of the cutting fluid on the thermo-mechanical tool loads as well as the chip formation process. The Finite Pointset Method will be used as simulation method due to its meshfree approach which provides the required flexibility for the mapping of free surfaces.