SPP 1480:  Modelling, Simulation and Compensation of Thermal Effects for Complex Machining Processes

In almost all machining processes, the components, which are to be manufactured, are to a large extent thermally affected. The thermal energy, which results in these processes mainly from shearing, friction and cutting energy, is dispersed to the workpiece, the chip, the cutting tool and the cooling lubricant. At the same time, the lubrication effect also reduces the frictional heat. In dry machining and minimum quantity lubrication, the cooling aspect does not exist and the lubrication is at least reduced.
Transient thermal fields, generated during the manufacturing process, and the heat, accumulating in the workpiece, cause a considerable impairment of the finished part with regard to tolerance compliance. Numerous dry processes or processes with minimum quantity lubrication induce a complex thermal load spectrum, which leads to thermally caused form deviations in the finished component and changes its behaviour in future use. Due to lack of fundamental knowledge, these influences can at the moment only be avoided by conducting extensive run-in experiments.
The primary objective of the Priority Programme is the modelling, simulation and compensation of thermal effects on the manufactured component. The aim is to avoid or compensate the manufacturing inaccuracies resulting from the process during the planning phase by using simulation-supported methods. The simulation, e.g., based on the finite element method, is an appropriate tool for this purpose since it can be used to calculate the thermomechanical behaviour of components by applying thermal and mechanical loads.
The investigations focus on all machining operations, but the definition of the problem is different for the individual production processes. The spectrum of examined components is comprised of geometrically complex shapes with a homogeneous material matrix and components with an inhomogeneous material structure, but always based on a metallic basic matrix. The objective is to be accomplished in three sequential phases of two years each. During the course of the Priority Programme, the complexity of the simulation models will be increased successively.

DFG Programme Priority Programmes

International Connection Austria

• Analysis of the heat input into the workpiece due to drilling and the resulting influences on the wall of the hole for 42CrMo4 (Applicant Schulze, Volker )
• Compensation strategies for thermal effects in dry milling and drilling (Applicants Büskens, Christof ;  Sölter, Jens )
• Coordination Funds (Applicant Biermann, Dirk )
• Coupling of analytical and numerical models to simulate the thermomechanical interactions during the milling of complex workpieces (Applicant Zäh, Michael Friedrich )
• Experimental and FEM-based Analysis of the thermal loads in deep-hole drilling process using twist drills and MQL (Applicant Biermann, Dirk )
• Experimentell basierte Modellierung, Simulation und Kompensation thermischer Einflüsse beim Drehen mesoheterogener Werkstoffe aus Al-MMC. (Applicants Aurich, Jan C. ;  Steinmann, Paul )
• Modeling and Compensation of Thermic Processing Influence for Short Hole Drilling (Applicant Eberhard, Peter )
• Modellierung, Simulation und Kompensation von thermischen Bearbeitungseinflüssen für komplexe Zerspanprozesse (Applicant Biermann, Dirk )
• Modelling and simulation of internal traverse grinding - from micro-thermo-mechanical mechanisms to process models (Applicants Biermann, Dirk ;  Menzel, Andreas )
• Modelling, simulation and compensation of thermal effects by hobbing gears (Applicants Halle, Thorsten ;  Karpuschewski, Bernhard )
• Numerical analysis and efficient implementation of complex FE-models for mechanical production processes using the example of deep hole drilling (Applicant Blum, Heribert )
• Prediction and compensation of the thermalelastic workpiece deformation in dry turning (Applicants Klocke, Fritz ;  Kneer, Reinhold )
• Simulation of Thermomechanically Caused Workpiece Deformations for the NC Milling Process (Applicants Schröder, Andreas ;  Zabel, Andreas )
• Thermal effects when turning Al-MMC - experiments and simulations (Applicants Aurich, Jan C. ;  Steinmann, Paul )
• Thermo-mechanical simulation of hard turning with macroscopic models and phase-field-models (Applicants Mahnken, Rolf ;  Uhlmann, Eckart )
• Thermomechanical Deformation of Complex Workpiece in Drilling and Milling Processes (Applicants Denkena, Berend ;  Maaß, Peter )

Spokesperson Professor Dr.-Ing. Dirk Biermann

Participating Persons Professor Dr.-Ing. Eberhard Abele; Professor Dr. Carsten Carstensen; Professor Dr.-Ing. Welf-Guntram Drossel; Professor Dr.-Ing. Knut Großmann (†); Dr.-Ing. Hans-Werner Hoffmeister; Professor Dr. Ulrich Maas; Professor Dr. Peter Maaß; Professor Dr.-Ing. Rolf Mahnken; Professor Dr.-Ing. Andreas Menzel; Professor Dr. Andreas Schröder; Professor Dr.-Ing. Andreas Schubert; Professor Dr.-Ing. Volker Schulze; Professor Dr.-Ing. Paul Steinmann; Dr.-Ing. Jens Sölter; Professor Dr.-Ing. Eckart Uhlmann; Professor Dr.-Ing. Andreas Zabel; Professor Dr.-Ing. Michael Friedrich Zäh