The project is being worked on as part of Priority Program 2231 "Efficient Cooling, Lubrication and Transport - Coupled Mechanical and Fluid Dynamic Simulation Methods for the Realization of Efficient Production Processes" together with the Institute of Machine Design and Tribology (IMKT) at the Leibniz Universität Hannover.
The first term of the project was recently completed. During this runtime, a planer test rig was expanded to include a coolant supply system that enables machining processes with coolant pressures of up to 70 bar. "With the help of this test rig and the associated high-speed camera, we were able to observe chip formation processes during machining with high-pressure cooling lubricant close to the effective point for the first time" explains project worker Lars Ellersiek. The chip formation process can be recorded by the high-speed camera with 12-fold magnification and slowed down by a factor of 1000. In the high-speed images, increased curvature of the chip as a result of the cooling lubricant as well as details of the penetration of the cooling lubricant into the lubrication gap can be seen. In addition, the use of cooling lubricant at high cutting speeds of 500 m/min changes the chip formation mechanism. Ellersiek: "As the cutting speed increases, without cooling lubricant the flow chip formation in our application develops into shear chip formation. This creates unfavorable dynamic loads on the tool."
Following the promising research results, the German Research Foundation (DFG) has approved a second term for the project. It will start at the beginning of 2023 and will focus on simulating the observed effects using the finite element method.
Currently, the DFG is still looking for a project manager for the project. If you are interested, you can find the appropriate call for proposals under the following link:
www.uni-hannover.de/de/jobs/id/5629;
Contact:
For further information, please contact Lars Ellersiek, Institute of Production Engineering and Machine Tools, by phone +49 511 762 18234 or by e-mail at ellersiek@ifw.uni-hannover.de.
