Thermal effects in complex machining processes : final report of the DFG Priority Programme 1480

404 Pages·2018·32.674 MB·English

by  Biermann, Dirk, Hollmann, Ferdinand

Lecture Notes in Production Engineering
D. Biermann
F. Hollmann Editors
Thermal Effects
in Complex
Machining
Processes
Final Report of the DFG Priority
Programme 1480
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D. Biermann F. Hollmann
Editors
Thermal Effects in Complex
Machining Processes
Final Report of the DFG Priority
Programme 1480
123
Editors
D.Biermann F. Hollmann
Institute of Machining Technology Deutsche Forschungsgemeinschaft
TU DortmundUniversity Bonn
Dortmund, Nordrhein-Westfalen Germany
Germany
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ISSN 2194-0525 ISSN 2194-0533 (electronic)
Lecture Notesin ProductionEngineering
ISBN978-3-319-57119-5 ISBN978-3-319-57120-1 (eBook)
DOI 10.1007/978-3-319-57120-1
LibraryofCongressControlNumber:2017938536
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Contents
Introduction... .... .... .... ..... .... .... .... .... .... ..... .... 1
D. Biermann and F. Hollmann
Part I Collaboration within the Working Groups
Temperature Measurements and Heat Partitioning in Machining
Processes . .... .... .... .... ..... .... .... .... .... .... ..... .... 5
J. Sölter, R. Frohmüller and H. Wirbser
Optimization and Compensation Strategies... .... .... .... ..... .... 23
A. Menzel and A. Schmidt
Material Modelling. .... .... ..... .... .... .... .... .... ..... .... 29
V. Schulze
Part II Final Reports of the Research Projects
Improvement of the Machining Accuracy in Dry Turning of
Aluminum Metal Matrix Composites via Experiments and Finite
Element Simulations.... .... ..... .... .... .... .... .... ..... .... 35
M. Zimmermann, S. Schindler, J.C. Aurich and P. Steinmann
Modelling and Compensation of Thermoelastic Workpiece
Deformation in Dry Cutting.. ..... .... .... .... .... .... ..... .... 63
F. Klocke, R. Kneer, M. Burghold, M. Deppermann, B. Peng and H. Puls
Thermo-Mechanical Simulation of Hard Turning with Macroscopic
Models... .... .... .... .... ..... .... .... .... .... .... ..... .... 95
E. Uhlmann, R. Mahnken, I.M. Ivanov and C. Cheng
Modeling of Orthogonal Metal Cutting Using Adaptive Smoothed
Particle Hydrodynamics. .... ..... .... .... .... .... .... ..... .... 133
F. Spreng and P. Eberhard
v
vi Contents
Experimental and Simulative Modeling of Drilling Processes for the
Compensation of Thermal Effects .. .... .... .... .... .... ..... .... 145
P. Bollig, J. Michna, C. Faltin, J. Schneider, F. Zanger, R. Schießl,
U. Maas and V. Schulze
Modelling, Simulation and Compensation of Thermomechanically
Induced Deviations in Deep-Hole Drilling with Minimum Quantity
Lubrication ... .... .... .... ..... .... .... .... .... .... ..... .... 181
D. Biermann, H. Blum, I. Iovkov, A. Rademacher, K. Rosin
and F.-T. Suttmeier
Thermomechanical Deformation of Complex Workpieces in Milling
and Drilling Processes... .... ..... .... .... .... .... .... ..... .... 219
B. Denkena, P. Maaß, A. Schmidt, D. Niederwestberg, J. Vehmeyer,
C. Niebuhr and P. Gralla
Compensation Strategies for Thermal Effects in Dry Milling ..... .... 251
M. Gulpak, H. Wernsing, J. Sölter and C. Büskens
Modeling, Simulation and Compensation of Thermomechanically
Induced Material Deformation in Dry NC Milling Processes ..... .... 289
T. Siebrecht, P. Wiederkehr, A. Zabel, M. Schweinoch, A. Byfut
and A. Schröder
Coupling Analytical and Numerical Models to Simulate
Thermomechanical Interaction During the Milling Process
of Thin-Walled Workpieces .. ..... .... .... .... .... .... ..... .... 321
S. Wimmer, J. Loehe and M.F. Zaeh
Modeling, Simulation and Compensation of Thermal Effects in Gear
Hobbing.. .... .... .... .... ..... .... .... .... .... .... ..... .... 347
M. Beutner, I. Kadashevich, B. Karpuschewski and T. Halle
Modelling and Simulation of Internal Traverse Grinding—From
Micro-thermo-mechanical Mechanisms to Process Models... ..... .... 369
R. Holtermann, S. Schumann, A. Menzel and D. Biermann
Introduction
D.BiermannandF.Hollmann
ThiscontributedvolumecontainsthesummarisedfinalresultsofthePriorityPro-
gramme (PP) 1480 “Modelling, Simulation and Compensation of Thermal Effects
for Complex Machining Processes”, which was funded by the German Research
Foundation (germ.: Deutsche Forschungsgemeinschaft—DFG) in the period from
2010 to 2016. Within the framework of this PP collaborative teams of machining
experts on the one hand and researchers from the fields of mechanics, thermody-
namics,mathematicsaswellasmaterialsscienceontheotherhandworkedtogether
onaninterdisciplinaryleveltosolvetheworkpiece-relatedproblemsresultingfrom
heateffectsincomplexmachiningoperations(seeFig.1).Variousprocesses,suchas
turning,milling,drilling,deepholedrilling,hobbingaswellasgrindingwereinves-
tigated by twelve research projects, which developed particular simulation-based
prediction and compensation methods for the minimisation of thermally induced
impactsonthecomponentmachined.
D.Biermann(✉)
CoordinatorofthePriorityProgramme1480,InstituteofMachiningTechnology,
BaroperStreet303,44227Dortmund,Germany
e-mail:[email protected]
F.Hollmann
ProgrammeDirectorEngineeringSciences,German
ResearchFoundation,Kennedyallee40,53175Bonn,Germany
e-mail:[email protected]
©SpringerInternationalPublishingAG2018 1
D.BiermannandF.Hollmann(eds.),ThermalEffectsinComplex
MachiningProcesses,LectureNotesinProductionEngineering,
DOI10.1007/978-3-319-57120-1_1
2 D.BiermannandF.Hollmann
Fig.1 Negativeinfluencesontheworkpiececausedbythermaleffectsduringmachining
Threeworkinggroups,focusingonmeasurementtechnology,modellingandsim-
ulationtechniquesaswellasonmaterialandfrictionmodelling,wereinitiatedatthe
beginning of the PP 1480 to promote the scientific exchange among the projects
by realising a wide range of activities such as meetings, workshops and round
robintests.Threeconsecutivelystagesensuredthestructuredattainmentofthepro-
grammesobjectives(Fig.2).
The first stage “feasibility” contains fundamental investigations aiming at the
determination of the process heat source as well as the initial modelling and sim-
ulationofitsimpactontheworkpiece.Withinthesecondprojectstagecalled“flex-
ibility”themodelswereenhancedandcomplexpartshapesaswellas,ifnecessary,
multipleheatsourceswereconsidered.Thelastthirdstageentitled“compensation”
utilisedthesimulationapproachesdevelopedinthefirsttwophasesfortheprediction
ofthermaldistortionandsubsurfacedamagecausedbythecorrespondingmachining
operation.Thefollowingchapterspresentasummaryoftheworkinggroupactivities
(Part1)andthefinalresultsoftheindividualresearchprojects(Part2).
Fig.2 StructureandobjectiveofthePriorityProgramme1480
Part I
Collaboration within the Working
Groups