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Modelling, Simulation and Compensation of Thermomechanically Induced Deviations in Deep-Hole Drilling with Minimum Quantity Lubrication

  • D. Biermann
  • H. Blum
  • I. Iovkov
  • A. Rademacher
  • K. Rosin
  • F.-T. Suttmeier
Chapter
Part of the Lecture Notes in Production Engineering book series (LNPE)

Abstract

This chapter summarises interdisciplinary research work on deep-hole drilling of aluminium casting using twist drills and minimum quantity lubrication (MQL). The high thermal conductivity of the workpiece material, the low cooling performance of MQL and the long main time of the process lead to a significant thermal load onto the workpiece. The thermal distortion of the machined component causes a systematic deflection of the long drilling tool and thus a high straightness deviation of the produced bore. Based on extensive technological investigations with a focus on the heat input into the workpiece a reliable simulation-based prediction of the thermomechanical distortion and the resulting bore deviations is presented. Thereby a finite element (FE)-model of the workpiece was coupled with a simple analytic representation of the deep-hole drilling tool. Using the fictitious domain method, adaptive techniques, and massive parallelisation, the FE-simulation is most efficiently realised. In order to compensate the occurring deviations, a novel approach based on radial tool path adjustment was developed, which allows for the drilling direction to be controlled during the process. The sophisticated simulations enable the determination of the optimal NC-path for the deep-hole drilling tool, which is not possible based on experiments. The validation results show a great potential of the developed methods for the simulation-based minimisation of the thermomechanically induced straightness deviation in deep-hole drilling.

Notes

Acknowledgements

This contribution is based on investigations in the research projects “Experimental and FE-based analysis of the thermal load on the tool and the workpiece in deep hole drilling using twist drills” (BI 498/24) and “Numerical analysis and efficient implementation of complex FE-models for the simulation of deep-hole drilling processes” (BL 256/11) within the Priority Programme 1480 “Modelling, Simulation and Compensation of Thermal Effects for Complex Machining Processes”, which are kindly funded by the German Research Foundation (DFG).

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Copyright information

© Springer International Publishing AG 2018

Authors and Affiliations

  • D. Biermann
    • 1
  • H. Blum
    • 2
  • I. Iovkov
    • 1
  • A. Rademacher
    • 2
  • K. Rosin
    • 2
  • F.-T. Suttmeier
    • 3
  1. 1.Institute of Machining Technology, TU Dortmund UniversityDortmundGermany
  2. 2.Chair of Scientific ComputingTU Dortmund UniversityDortmundGermany
  3. 3.Work Group Scientific ComputingUniversity of SiegenSiegenGermany

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