TRR 96:  Thermo-Energetic Design of Machine Tools - A Systemic Approach to Solve the Conflict between Power Efficiency, Accuracy and Productivity Demonstrated at the Example of Machining Production

• Subject Area: Materials Science and Engineering ; Computer Science, Systems and Electrical Engineering ; Mechanical and Industrial Engineering ; Mathematics ; Social and Behavioural Sciences ; Thermal Engineering/Process Engineering
• Term: from 2011 to 2023
• Website: Homepage
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 174223256

The challenge of research in the CRC/TR 96 derives from the attempt to satisfy the conflicting goals of reducing energy consumption and increasing accuracy and productivity in machining. The solution approach pursued is based on measures that make it possible to guarantee process accuracy despite increasing power losses without additional energetic measures under thermal transient environmental conditions and under operating conditions characterized by individual and small series production. The scientists of the CRC/TR 96 are researching and developing effective correction and compensation solutions for the thermo-elastic machine behavior, which will enable precision machining under the future conditions of energy-efficient production.The following subgoals are derived from this:1) Development of modeling fundamentals for a comprehensive calculation capability of thermo-elastic deformations and the heat fluxes causing them, as well as for the mapping of structural variability due to relative movements and minimization of calculation time,2) Implementation of a current data image as a digital representation of the thermo-elastic functional chain. This includes model data as well as parameters and provides for the possibility of a cyclic update.3) Recording of the effects of heat sources and sinks on the thermal behaviour of machine tools as well as the description of the temporal behaviour. Tracking of locally and temporally fluctuating parameters by means of parameter identification procedures as a prerequisite for the design and operation of correction and compensation approaches,4) Development of basic metrological approaches for the detecting of thermo-elastic failures in specified structural areas of machine tools and their use for correction and compensation solutions,5) Development and implementation of solutions for the control-integrated correction of thermo-elastic failures under consideration of process-accompanying data analysis.6) Development and integration of design and material property-supported approaches for the compensation of thermo-elastic effects by stabilisation of the temperature field and reduction and homogenisation of the heat energy input in the area of load-bearing structures, 7) Technical-economic evaluation of the measures developed in the SFB/TR 96 with regard to their impact on product quality, volume performance, energy consumption and costs.In phase 3 (demonstration phase), the research work relates to the entire machine. On the basis of the research results on simple partial and overall models, correction and compensation approaches are transferred to the application for the entire machine under the conditions of real operation. This leads to new scientific challenges due to a multitude of uncertainties and parameter fluctuations. The models have to be further developed and new solutions for the control of variable operating conditions such as online identification have to be developed.

• DFG Programme: CRC/Transregios
• International Connection: Austria

Current projects

• T09 - Design and Optimization of Cooling Structures in Compact Drives Based on Simulated 3D-Temperature Fields (Project Heads Ihlenfeldt, Steffen ;  Weber, Jürgen )
• T12 - Modelling of dual-phase fluid-solid interactions in the workspace of cutting machine tools to enable process-specific thermal error compensation (Project Heads Glänzel, Janine ;  Regel, Joachim )
• T14 - Simulation-based optimization of the milling process by regulating the tool temperature - knowledge transfer project (Project Heads Bergs, Thomas ;  Kneer, Reinhold )
• T15 - Data based ... (Project Head Brecher, Christian )
• T16 - Sustainability-centered control of active cooling systems of spindles in machine tools (Project Head Brecher, Christian )
• T21 - Thermally robust lightweight construction through hybrid optimization (Project Head Ihlenfeldt, Steffen )
• T22 - Sensory spindle system for correcting the thermally induced TCP deviation as a function of varying thermal loads (short title: Sensory spindle system) (Project Heads Dix, Martin ;  Regel, Joachim )

Completed projects

• A01 - Deformations of cutting tool and clamping devices and workpiece fixture devices and of the impact on cutting edge and workpiece deflections targeting on their optimization and compensation (Project Heads Drossel, Welf-Guntram ;  Neugebauer, Reimund ;  Putz, Matthias ;  Regel, Joachim ;  Schmidt, Gerhard )
• A02 - Model and method for the determination and distribution of converted energies in milling processes (Project Heads Bergs, Thomas ;  Klocke, Fritz ;  Mattfeld, Patrick ;  Veselovac, Drazen )
• A03 - Model and method for the determination and distribution of converted energies in grinding processes (Project Heads Bergs, Thomas ;  Klocke, Fritz ;  Mattfeld, Patrick ;  Wegner, Hagen )
• A04 - Thermo-energetic description of fluid power systems (Project Head Weber, Jürgen )
• A05 - In-process system simulation of machine tool models (Project Heads Beitelschmidt, Michael ;  Ihlenfeldt, Steffen ;  Stelzer, Ralph )
• A06 - model order reduction (Project Heads Benner, Peter ;  Saak, Jens )
• A07 - High-accuracy thermo-elastic simulation on massively parallel computers (Project Heads Voigt, Axel ;  Wensch, Jörg )
• B01 - Modelling of the thermal interaction between the environment and the machine tool and the effected deflection of the machine tool in order to deduce methods of design and compensation for a better thermal behaviour (Project Heads Drossel, Welf-Guntram ;  Neugebauer, Reimund )
• B02 - Calculation and modelling of heat transfer mechanisms between machine components (Project Head Kneer, Reinhold )
• B03 - Investigation of components and assembly groups (Project Head Brecher, Christian )
• B04 - Identification of exemplary scattering and time-varying thermal model parameters (Project Heads Hellmich, Arvid ;  Ihlenfeldt, Steffen ;  Kabitzsch, Klaus ;  Kauschinger, Bernd )
• B05 - Correction by Characteristic Diagrams (Project Heads Herzog, Roland ;  Priber, Ulrich )
• B06 - Property model based correction of load dependent machine tool deformations (Project Head Brecher, Christian )
• B07 - Structure model based correction of thermo-elastic errors at machine tools (Project Heads Fetzer, Christof ;  Ihlenfeldt, Steffen ;  Kauschinger, Bernd ;  Mühl, Andreas ;  Weber, Jürgen )
• B08 - Model predictive parameter and state estimation and optimal sensor placement (Project Heads Herzog, Roland ;  Stoll, Martin )
• B09 - Identification of environment parameters of thermo-elastic models and correction algorithms based on high-dimensional characteristic diagrams (Project Heads Glänzel, Janine ;  Ihlenfeldt, Steffen ;  Putz, Matthias )
• B10 - Controller data based feed forward temperature field control of a machine tool (thermal pre-control) (Project Head Ihlenfeldt, Steffen )
• C02 - Modelling and design of systems for active control of temperature distribution in frame subassemblies (Project Heads Drossel, Welf-Guntram ;  Neugebauer, Reimund )
• C03 - Concept to determine thermo-elastic deformations by directly measuring local shifts using structurally integrated sensors (Project Heads Brecher, Christian ;  Wenzel, Christian )
• C04 - Modelling and optimisation of power losses in electrical drives and their thermal coupling with machine tools (Project Head Werner, Ralf )
• C05 - Model based method for the evaluation of the solution variants in design and realisation in particular under thermal-energetic, qualitative and economic aspects (Project Heads Esswein, Werner ;  Wiemer, Hajo )
• C06 - Measurement of behavior and operating state relevant values along the thermal effect-chain for analy-sis, evaluation, simulation and correction on the example of a specific test bed machine. (Project Heads Müller, Jens ;  Stelzer, Ralph )
• T01 - Modelling of the thermo-elastic behavior of an externally driven spindle system (Project Head Fey, Marcel )
• T02 - Robust and Thermo-energetically Optimized Temperature Control of Machine Tools' Frames by Means of Fluid Power Systems (Project Heads Ihlenfeldt, Steffen ;  Weber, Jürgen )
• T05 - Efficient simulation technology for the analysis of the thermo-elastic behaviour of compact assemblies of machine tools (Project Head Ihlenfeldt, Steffen )
• T11 - Data based investigation of the thermo-elastic TCP-Error using neural networks (DataNet) (Project Head Brecher, Christian )
• Z01 - Administration (Project Head Brecher, Christian )
• Z02 - Demonstration (Project Head Ihlenfeldt, Steffen )

• Applicant Institution: Technische Universität Dresden
• Participating Institution: Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik ; Außenstelle Dresden; Fraunhofer-Institut für Produktionstechnologie (IPT); Fraunhofer-Institut für Werkzeugmaschinen und Umformtechnik (IWU)
• Co-Applicant Institution: Rheinisch-Westfälische Technische Hochschule Aachen; Technische Universität Chemnitz
• Spokesperson: Professor Dr.-Ing. Christian Brecher, since 1/2015