SPP 2231:  Efficient cooling, lubrication and transportation – coupled mechanical and fluid-dynamical simulation methods for efficient production processes (FLUSIMPRO)

• Subject Area: Mechanical and Industrial Engineering ; Materials Science and Engineering ; Thermal Engineering/Process Engineering
• Term: since 2020
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 422633203

Fluids are used as cooling lubricants in almost all production processes. In addition to the machine technology used, the process control variables, the tools and the materials processed, the cooling lubricant is one of the crucial process influencing factors. A detailed understanding of the behaviour of coolants, especially when machining demanding materials, is therefore essential for their targeted and efficient use. However, the relevant length and time scales can only be insufficiently analysed using experimental methods, so that the development of new methods for complete process simulation is necessary in order to map in detail the complex processes involved in the use of fluids in production processes, which is crucial to be able to exploit the full potential of the use of coolant lubricants. From the problem described above, the major objective of the priority programme (PP) is to create the necessary fundamentals through interdisciplinary cooperation and to implement coupled mechanical and fluid-dynamic simulation methods. The focus is exclusively on production processes in which the coolant lubricant takes over cooling, lubricating and transporting functions, for example of chips, charge carriers, abrasives or reaction products. In the research network of the SPP 2231, the coordination of joint activities to achieve the main objective of the priority programme is of great importance. The first funding period showed the great potential and added value of networking within the entire SPP as well as the working groups. Several meetings have taken place and bilateral as well as cross-project activities and synergies could be realized. In addition to the project presentations, the first interim colloquium reported on the progress of the working groups and discussed the planned activities, which include further meetings and workshops of the three working groups during the first period. The SPP coordination requires a high level of communication to coordinate and organize the internal processes, e.g. kickoff meetings, setting up different mailing lists, setting up and maintaining a website for public relations, planning and coordination of working group meetings, workshops, scheduling, invitations, interim colloquium etc.. Therefore, especially the subject-specific coordination work of the coordinator should be accompanied or supported by a scientific staff member, so that the smooth implementation of the events in terms of the main objectives of the SPP group (e.g. kickoff, working groups, workshop, interim and proposal colloquium, etc.) can be ensured.

• DFG Programme: Priority Programmes
• International Connection: Austria

Projects

• Coordination Funds (Applicant Biermann, Dirk )
• Coupled multi-physics simulation methods for control of PECM processes with Magnetic-Field-Assistance (MPECM) (Applicants Richter, Markus ;  Schubert, Andreas )
• Coupling of experimental and numerical methods for multiscale analysis and modelling of coolant influences and mechanism in cutting processes (KExNuMe-KSS) (Applicants Denkena, Berend ;  Poll, Gerhard )
• Efficient coolant lubricant application in narrow kerfs when sawing titanium alloys by simulation of thermal and mechanical fluid-solid interactions (Effi-Ti-Sim) (Applicants Kabelac, Stephan ;  Möhring, Hans Christian )
• Fully coupled fluid-structure-contact simulations to understand the processes in the contact zones during lubricated orthogonal cutting (Applicants Elgeti, Stefanie ;  Zabel, Andreas )
• Integral coupled simulation of fluid dynamics of the metal cutting fluid and the cutting process in vibrationn assisted drilling - ViBohr (Applicants Fritsching, Udo ;  Karpuschewski, Bernhard )
• Modelling of the cooling effect in tool grinding under consideration of process-related uncertainties (Applicants Bergmann, Benjamin ;  Schmidt, Alfred )
• Multi-scale modeling of the thermal workpiece load in the turning process considering the cutting fluid (Applicants Bergs, Thomas ;  Kneer, Reinhold )
• Multiphase modelling of cutting fluid and its aerosols in cutting simulations using the Finite Pointset Method (FPM) for analysing the mechanisms of action (MultiCuttingFluid) (Applicants Kuhnert, Jörg ;  Sommerfeld, Martin ;  Uhlmann, Eckart )
• Numerical multiscale modelling and optimization of cooling concepts in gear skiving (Applicants Bauer, Hans-Jörg ;  Moseler, Michael ;  Schulze, Volker )
• Simulation and optimization of the coolant flow to reduce the thermal tool load during discontinuous drilling of Inconel 718 (Applicants Biermann, Dirk ;  Turek, Stefan )
• Simulation of the pulsed electrochemical machining (PECM) of thin-walled workpieces for turbomachinery component manufacturing – SIMPECT (Applicants Klink, Andreas ;  Schröder, Wolfgang )
• Tool and Process Optimization for efficient Ejector Deep-Hole Drilling-Processes using Smoothed Particle Hydrodynamics (SPH) (Applicants Biermann, Dirk ;  Eberhard, Peter )

• Spokesperson: Professor Dr.-Ing. Dirk Biermann