In interdisciplinary cooperation a model will be developed, which enables the simulation of the thermomechanical workpiece deformation during machining. Using this model the prediction of thermal induced shape deviations will be possible. A discrete workpiece model will be established, which is built up from a Dexel-based material removal calculation and a Finite Element (FE) Model. The former enables the calculation of the actual geometrical workpiece deformation and the analysis of the contact geometry between tool and workpiece during cutting process. The calculated heat-flow into the workpiece and the removed volume are handed-over to the FE-Model. This is able to calculate the resulting thermo-mechanical workpiece deformation as well as to update its model shape according to the material removed by the cutting tool. The discrete model will be valid for continuous (drilling) and discontinuous (milling) process. In the first two years fundamental investigations on geometrical simple workpieces have been carried out. In the second part of the project the scope of these investigations was extended to complex workpieces. As a result the thermo-mechanical deformation of structural workpieces was predicted. Finally the thermal effects will be compensated by changing the process parameters and the NC-Toolpath. This is the overall goal of the project that will be reached after the third period of funding.
DFG Programme
Priority Programmes
