Modeling and Compensation of Thermic Processing Influence for Short Hole Drilling

• Applicant: Professor Dr.-Ing. Peter Eberhard
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: from 2010 to 2016
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 178689393

Both the dimensional accuracy and the surface quality of a manufactured component are considerably influenced by the warming of the workpiece occurring during the machining process in short hole drilling. In the course of the six-year project, it is intended to develop a coupled simulation tool, based on the Smoothed Particle Hydrodynamics (SPH) particle method and the Finite Element Method (FEM). With this tool, it will be possible to model the aforementioned thermal effects as well as the resulting loads on the manufactured workpiece for the short hole drilling process. The main aim of this research project is to work out simulation-assisted compensation principles for the deformations of components with geometrically complex shapes arising due to thermal loads in short hole drilling.Based on the findings gained from the simulations and experimental investigations carried out during the first two phases of this project, a dynamically and synchronously coupled SPH/FEM model focusing on the short hole drilling process is developed in the third funding period. Following this, the process model worked out will be validated with the results of the experimental tests on components with geometrically simple as well as complex shape. That way, it is intended to create an adequate, thermomechanically coupled simulation tool in the third project phase, which will be used to find compensation principles minimizing the thermal influences observed during the process of machining with geometrically defined cutting edge. Towards the end of the two-year project phase and, thus, also of the overall research project, the previously developed compensatory measures for short hole drilling are validated based on simulations as well as experimental investigations.

• DFG Programme: Priority Programmes
• Subproject of: SPP 1480: Modelling, Simulation and Compensation of Thermal Effects for Complex Machining Processes
• Participating Person: Dr.-Ing. Thomas Stehle