SPP 1480: Modelling, Simulation and Compensation of Thermal Effects for Complex Machining Processes

Type of Funding: DFG Programmes, Priority Programmes

In almost all machining processes, the components, which are to be manufactured, are to a large extent thermally affected. The thermal energy, which results in these processes mainly from shearing, friction, and cutting energy, is dispersed to the workpiece, the chip, the cutting tool, and the cooling lubricant. At the same time, the lubrication effect also reduces the frictional heat. In dry machining and minimum quantity lubrication, the cooling aspect does not exist and the lubrication is at least reduced. Transient thermal fields, generated during the manufacturing process, and the heat, accumulating in the workpiece, cause a considerable impairment of the finished part with regard to tolerance compliance. Numerous dry processes or processes with minimum quantity lubrication induce a complex thermal load spectrum, which leads to thermally caused form deviations in the finished component and changes its behavior in future use. Due to lack of fundamental knowledge, these influences can at the moment only be avoided by conducting extensive run-in experiments. The primary objective of the priority program is the Modelling, Simulation and Compensation of Thermal Effects on the manufactured component. The aim is to avoid or compensate the manufacturing inaccuracies resulting from the process during the planning phase by using simulation-supported methods. The simulation, e.g., based on the finite element method, is an appropriate tool for this purpose since it can be used to calculate the thermomechanical behavior of components by applying thermal and mechanical loads. The investigations focus on all machining operations, but the definition of the problem is different for the individual production processes. The spectrum of examined components is comprised of geometrically complex shapes with a homogeneous material matrix and components with an inhomogeneous material structure, but always based on a metallic basic matrix. The objective is to be accomplished in three sequential phases of two years each. During the course of the priority program, the complexity of the simulation models will be increased successively.

Project Website

Contact Person at UA Ruhr:
Prof. Dr.-Ing. Dirk Biermann, TU Dortmund University

UA Ruhr Researchers:
Prof. Dr.-Ing. Andreas Menzel, TU Dortmund University
Dr. Andreas Rademacher, TU Dortmund University
Jun.-Prof. Dr.-Ing. Petra Wiederkehr, TU Dortmund University
Dr.-Ing. Andreas Zabel, TU Dortmund University

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