Modeling and compensation of thermoelastic workpiece deformation in dry cutting


Dry machining is one of the most significant developments in manufacturing technology. One main problem in comparison to machining with coolants is that dry machining creates much stronger heating in the workpiece, resulting in shape and dimensional deviations. It is not possible until now, originating from blank contour, depending on processes sequences and cutting conditions, to continuously calculate the expected shape and dimensional deviaitons in dry machining. Regarding to previous studies the heat source and the heat partition were mostly estimated by experiments. The objective of the research project is development of a numerical multiscale model to calculate the thermo-elastic workpiece deformation and to finally compensate these deformations in dry machining of workpiece. The innovative approach is therein by the usage of multiphysics simulation with Finite Element Method, calculating the heat source and the heat partition in the chip formation process as a function of machining parameters. With the prediction of heat source, the FEM calculation of thermally induced deformation of the workpiece is carried out.

In order to realize this objective, a multiscale model of dry turning was developed in the project phases. This includes two sub-models, a chip formation model and a workpiece model to consider the relevant physical phenomena at time and spatial scales. In chip formation model, thermo-mechanical energy comsumption of the process and in particular the heat partition into the workpiece are calculated and then both are implemented on to the workpiece model. The further sub-models of the chip formation simulation are researched to describe the frictional processes and heat transfer in the contact zones between tool, chip and workpiece. Experimental thermal analysis of the respective processes is conducted, to determine the heat fluxes by inverse calculation of heat transfer problems.

The project partners would like to thank the German Research Foundation (DFG) for funding the research project to develop a multiscale model for calculating and compensating thermo-elastic shape and dimensional deviations in dry machining with priority program (SPP 1480).


Do you have questions concerning this project?

Your contact:
Bingxiao Peng, M.Sc. RWTH
Cluster Produktionstechnik 3A 238
Tel.: +49 241 80-28181
Fax: +49 241 80-22293


Markus Meurer, M.Sc. RWTH
Workgroup Leader
Cluster Produktionstechnik 3A 254
Tel.: +49 241 80-28040
Fax: +49 241 80-22293