Project Details
Projekt
Developing the design and technological basis for the manufacture and use of circular saw blades with internal cooling lubricant channels
Subject Area
Metal-Cutting and Abrasive Manufacturing Engineering
Term
since 2026
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 572498388
The goal of this research project is to holistically develop, analyze, and qualify circular saw blades with an internal coolant supply (ICS) for industrial use. The focus is on both the manufacturing of the tools and their evaluation using commercially available circular sawing machines. Building on the findings of the preceding DFG project (“FluSimPro”), the project will establish a sound understanding of the design and technological fundamentals, with the objective of further developing these insights and preparing them for future industrial implementation. The project is divided into three main areas of work. The first focuses on manufacturing circular saw blades with integrated coolant channels. First, the design constraints are analyzed, and then suitable points within the production chain for integrating coolant channels are identified. We will investigate various channel manufacturing methods, such as deep-hole drilling and slot milling. We will examine their interactions with hardness and residual stress profiles and their influence on blade geometry, including potential distortions caused by material removal. Based on these analyses, prototypes with different channel geometries and manufacturing technologies will be developed. These prototypes are then used to evaluate the impact on the static, dynamic, geometric, and fluid dynamic behavior of the saw blades. The second area addresses the optimal transfer of coolant to the saw blade and adapting commercial sawing machines to ICS technology. For a segment-wise coolant supply system, adjustable pressure and flow rates are developed to enable demand-oriented, resource-efficient coolant supply. These parameters are optimized using CFD simulations. The goal is to adapt the coolant supply dynamically based on process variables, such as cutting force or workpiece geometry. The third area involves applying and validating the developed ICS saw blades under real operating conditions. We systematically compare the performance, wear behavior, and effects of internal cooling to those of a conventional external coolant supply. These findings will contribute to a deeper understanding of the interactions between fluid and chip formation processes during sawing, and will be disseminated through scientific publications and presentations at conferences and trade fairs.
DFG Programme
Research Grants (Transfer Project)
Application Partner
AKE Knebel GmbH & Co. KG; KASTO Maschinenbau GmbH & Co. KG
