Project Details
Projekt
Simulation-based tool optimization as a basis for the production and efficient use of flow-optimized ejector drill heads
Subject Area
Metal-Cutting and Abrasive Manufacturing Engineering
Term
since 2025
Project identifier
Deutsche Forschungsgemeinschaft (DFG) - Project number 572500519
Increasing challenges in terms of energy costs and the demand for sustainable and efficient machining processes are shifting the focus in the optimization of machining processes to the energy-intensive area of cooling lubricant supply. In ejector deep hole drilling in particular, the coolant supply offers great potential for optimization in the implementation of resource-efficient processes due to the high pressures and large volume flows for cooling and lubricating the cutting edges and ensuring reliable chip transport from high drilling depths. In current industrial use, however, the process is often associated with high volume flows to ensure the ejector effect and safe chip transport. In basic investigations in the project “Tool and process development for efficient ejector deep drilling processes using smoothed particle hydrodynamics (SPH)” as part of the SPP 2231 FluSimPro, the ISF and ITM have succeeded in gaining corresponding process knowledge and an in-depth understanding of the interactions and flow conditions in the coolant supply of the ejector drilling process. Experimental and metrological analyses of the coolant flow and smoothed particle hydrodynamics (SPH) flow simulations have already been used to develop, implement and validate tool optimizations. The aim of this transfer project is therefore to transfer the findings from the basic investigations to tool manufacture and the efficient use of optimized ejector drill heads with different drill head bodies and tool diameters for machining various materials in an industrial environment. Based on a targeted simulation-based analysis with a focus on the influence of small tool diameters and only one chip mouth in the drill head, tool optimization is carried out with regard to coolant flow and chip transport. In order to consider the manufacturing costs as a factor for the acceptance of the optimized tools, both adapted drill head designs that can be produced by conventional and comparatively inexpensive machining are evaluated, as well as designs based on the extended possibilities of additive manufacturing. Finally, an energy consumption and cost analysis will evaluate the advantages that can be achieved in each case in terms of reducing pressure and volume flow in the drilling process, thus qualifying the ejector drilling process with optimized ejector drill heads as an efficient and sustainable deep hole drilling process for various diameters and materials. The cooperation with the companies botek Präzisionsbohrtechnik GmbH, Gontermann-Peipers GmbH and Harburg-Freudenberger Maschinenbau GmbH ensures the support and influence of the expertise of industrial partners from the development, design, construction and production to the application of optimized ejector drill heads.
DFG Programme
Research Grants (Transfer Project)
Application Partner
Gontermann-Peipers GmbH; Harburg-Freudenberger Maschinenbau GmbH; botek Präzisionsbohrtechnik GmbH
