Lightweight and vibration reduced hybrid FRP-metal drill tubes with structure-integrated sensor technology for BTA deep hole drilling processes

BTA深钻是一种用于生产具有高长径比的孔的工艺。然而，所需的工具长度导致工具系统振动的趋势增加。钻削过程中强烈的扭转振动主要发生在高合金材料的加工过程中，这会导致切削刃和导向垫的磨损增加以及钻削质量降低。通过由纤维增强塑料（FRP）的不均匀结构产生的振动阻尼来改善动态性能提高了工艺可靠性，并且因此由于通常高的部件成本而具有大的市场潜力。 基于有前途的初步调查，因此，混合玻璃钢钻杆将在本项目中开发。除了在优先方案“轻型结构用本征混合复合材料”的框架内从BTA深钻（ISF）的基本研究中获得的经验以及在金属碳纤维增强塑料轻型结构的制造、使用和监测方面获得的经验之外，（LKT，Fraunhofer IZFP），与CarboFibretec公司的合作，BGTB和Kaiser Maschinenbau und Zerspanungstechnik确保工业合作伙伴的支持和专业知识，钻杆的设计和制造最多的应用和验证。除了直接影响深钻过程，从而除了工具磨损和钻孔质量外，FRP钻杆的开发还关注纤维复合材料的材料特性（层压结构、冷却剂润滑剂影响、混合连接元件）以及复合材料中作用的载荷的传感记录，以使其符合工业用途。将FRP用于工具系统需要研究基体和纤维与其他机器部件的相互作用，例如在密封件或阻尼系统上的接触点区域，以及与冷却剂和切屑的相互作用。此外，为了使用结构集成的传感器技术，必须在传感器纤维的连接方面开发纤维缠绕工艺，同时对纤维复合材料的影响尽可能小。在该项目的框架内，进行了全面的实验和仿真支持的研究，以优化振动，并使层压结构适应切割过程。纤维与金属直接接触的腐蚀过程需要开发用于永久连接金属部件的混合连接系统。借助于到钻头中的传感器和钻管的层压件中的传感器的数据线，研究重要过程变量和临界载荷情况的过程并行记录，以及因此工具系统的状态监测。

BTA deep drilling is a process for producing bores with high length-to-diameter ratios. However, the required tool lengths lead to an increased tendency of the tool system to vibrate. Strong torsional vibrations during drilling, which occur primarily during the machining of high-alloy materials, lead to increased wear of the cutting edges and guide pads as well as to a reduced drilling quality. An improvement of the dynamic behavior through the vibration damping resulting from the inhomogeneous structure of fiber-reinforced plastics (FRP) increases the process reliability and thus has a large market potential due to the typically high component costs. Based on promising preliminary investigations, a hybrid FRP drill tube is therefore to be developed in this project. In addition to the experience gained from basic investigations on BTA deep drilling (ISF) and the experience gained in the manufacture, use and metrological monitoring of metal CFRP lightweight structures within the framework of the priority programme "Intrinsic hybrid composites for lightweight structures" (LKT, Fraunhofer IZFP), the cooperation with the companies CarboFibretec, BGTB and Kaiser Maschinenbau und Zerspanungstechnik ensures the support and the expertise of industrial partners from the development, design and manufacture of the drill tube up to the application and validation.In addition to the direct influence on the deep drilling process and thus on tool wear and hole quality, the development of the FRP drill tube also focuses on the material-specific properties of fibre composites (laminate structure, coolant lubricant influence, hybrid connecting elements) and the sensory recording of the loads acting in the composite in order to qualify it for industrial use. The use of FRP for tool systems requires investigations of the interactions of the matrix and the fibres with other machine components, e.g. in the area of seals or contact points on the damping system, as well as with coolants and chips. In addition, for the use of structure-integrated sensor technology, the fibre winding process must be developed with regard to the connection of the sensor fibres with as little influence as possible on the fibre composite. Within the framework of the project, comprehensive experimental and simulation-supported investigations are carried out to optimize vibration and to adapt the laminate structure to the cutting process. Corrosion processes in direct contact between fibres and metal require the development of hybrid joining systems for the permanent bonding of metallic components. With the help of a data line to sensors in the drill head and sensors in the laminate of the drill tube, the process-parallel recording of important process variables and critical load cases and thus a condition monitoring of the tool system are investigated.