Simulation of thermo-elastic workpiece deformation using machine internal data

• Applicant: Professor Dr.-Ing. Christian Brecher
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 537921543

The demands on the productivity and availability of machine tools and the quality of the products manufactured on them are constantly increasing. At the same time, there is growing pressure to reduce the environmental footprint of the machine tool from socio-economic and political stakeholders. To meet these demands, manufacturing defects in the machining of workpieces must be reduced. By reducing manufacturing errors, it is possible to reduce scrap and thus increase machine tool productivity. A large portion of manufacturing error is caused by the thermo-elastic behavior of the machine-workpiece system. While thermo-elastic machine behavior is already extensively covered in the literature, only limited valid models exist for thermo-elastic workpiece behavior. In the planned research project, a model for calculating the displacement field of a workpiece will be developed. For this purpose, an existing software at the WZL for the simulation of material removal will be extended by program modules with which the temperature and displacement field of the workpiece can be calculated. Based on this, the calculation result is then used to compensate for the thermo-elastic strain by means of control technology on a demonstrator at the WZL and thus improve the component quality. By improving the component quality, the production scrap can be reduced, which leads to a lower use of material and resources and thus to a more sustainable production.

• DFG Programme: Research Grants