SPP 2231 FLuSimPro – Coupling of experimental and numerical methods for the multi-scale analysis of the mechanisms of action of cooling lubrication strategies in machining processes (KexNuMe-KSS)

The supply of cutting fluid involves a high energy demand of the high-pressure pumps. But a reduction in the volume flow of CF leads to changes in the thermomechanical load. Currently, the design of the CF-supply is only possible through time-consuming and costly cutting experiments. Knowledge about the effect of the CF-supply on the local thermomechanical stress of the cutting wedge enables the knowledge-based design of CF-supply conditions and the transfer of singular knowledge to a practical and mechanism-based design methodology. As a result, tool manufacturers and users are enabled to optimize processes in terms of energy and tool costs.

Objectives

The aim of the project is to understand the effect of cutting fluids on the entire tribological system at the cutting wedge and to derive an energy-efficient CF-supply-strategy for optimizing turning tools and processes. To this end, knowledge about the influence of the CF on the spatially resolved thermomechanical cutting wedge load is to be gained.  This will result in numerous practical advantages:

• Availability of measurement methods for thermal and mechanical cutting wedge load with CF-supply at up to p = 95 bar
• Availability of basic knowledge of the mechanisms of action of cutting fluids for tool design
• Availability of a design methodology for the cooling lubricant supply
• Energy savings of up to 89 % for the CF-pump thanks to targeted optimization of CF-supply conditions

Benefits

The methods developed in subproject 05 of SPP2231 for the in-situ analysis of the thermomechanical cutting wedge load when cutting fluid is applied clearly show the direct effect of the CF on the friction and temperature at the cutting wedge.

Approach

In cooperation with the IMKT of the LUH, the thermomechanical, tribological and tribochemical effect of cutting fluid on the cutting wedge is being researched. Novel in-situ measurement methods are being developed and expanded for this purpose. The thermal cutting wedge load is measured using thermography with a resolution of 1.9 µm/px in a measuring field of 600 x 400 µm. Chip formation is analyzed at speeds of up to 500 m/min with up to 150,000 images per second. The IMKT carries out tribometer tests and develops a micro-contact simulation model of friction on the cutting wedge with CF.

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Contact Jan Schenzel via email at schenzel@ifw.uni.hannover.de or by phone at +49 511 762 4299.