Modelling of dual-phase fluid-solid interactions in the workspace of cutting machine tools to enable process-specific thermal error compensation (T12#)

• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering ; Engineering Design, Machine Elements, Product Development ; Production Automation and Assembly Technology ; Fluid Mechanics
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 174223256

The aim of T12 is the transfer of characteristic diagram based thermal error compensation of machine tools to the industrial application. Since this regression analysis based method is highly dependent on the quality of its training data, a realistic simulation of the thermal and thermo-fluidic conditions within the workspace will be developed within T12. A three-part model comprising a fluid structure interaction model of the cutting zone, a CFD model of the remaining workspace and a thermo-elastic machine model will realistically simulate the interactions between the machine and the dual-phase fluid of air and cooling lubricant. Additional temperature sensors will be used to integrate the resulting, more complex load cases into the error compensation models and thereby make the process-dependent thermal error prediction more reliable. Measurements will serve to parametrize and validate the simulation and compensation models.

• DFG Programme: CRC/Transregios (Transfer Project)
• Subproject of: 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
• Applicant Institution: Technische Universität Dresden
• Project Heads: Dr.-Ing. Janine Glänzel; Dr.-Ing. Joachim Regel