Thermally robust lightweight construction through hybrid optimization (T21#)

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

The machine tool industry faces the challenge of increasing the productivity and accuracy of its machines while at the same improving the contribution to reducing greenhouse gases over the entire product lifecycle. Thermal errors are becoming increasingly important in the optimization of machine tools as they can affect the performance and accuracy of the machines. State of the art approaches to increase productivity and energy efficiency by improving the thermal stability of machine components or by using lightweight components have been identified. However, thermal deformation and the interactions between mechanical and thermal behavior pose a challenge, especially in lightweight design. One hypothesis of this project proposal is that neglecting the interactions between the two behavioral domains means that the optimal structure for dynamic behavior may not be the optimal structure for thermal behavior and vice versa. The research project aims to develop an optimization method that considers both the thermal and the dynamic behavior of machine tools and integrates the interactions between the two aspects. It is planned to use a coupled analysis method based on fast computing, physically based thermo-elastic models from the Collaborative Research Centre/Transregio. The solution path initially involves separate optimization of the dynamic and the thermal behavior. Specific methods and algorithms are used for each domain. These methods are then combined into a cascaded, multi-criteria optimization method. Criteria such as mass, stiffness, temperature shift and thermally induced deformations are taken into account. The aim is to find a machine tool structure that meets both the dynamic and thermal requirements. Dynamic, thermal and thermo-elastic models are integrated to account for the interactions between the different behaviors. Order-reduced FE models and nodal models are used to efficiently calculate the temperature field. This integration forms the basis for the hybrid optimization of the machine tool structure. By developing a coupled optimization method that takes into account both dynamic and thermal behavior, the project will help to increase the productivity, accuracy and energy efficiency of machine tools. The research will make an important contribution to reducing greenhouse gas emissions and helping the machine tool industry move towards a sustainable future.

• 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 Head: Professor Dr.-Ing. Steffen Ihlenfeldt