Finite Element Model to Calculate the Thermal Expansions of the Tool and the Workpiece in Dry Turning

Schindler, Stefan; Zimmermann, Marco; Aurich, Jan C.; Steinmann, Paul

doi:10.1016/j.procir.2014.03.087

Cited by 9 publications

(7 citation statements)

References 12 publications

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“…The experimental investigations are similar to earlier investigations of the authors using the homogeneous matrix material of the present AL-MMC in [17] and the composite material in [25]. In the following, the fundamentals of the experimental design are repeated for a self-contained contribution.…”

Section: Experimental Designmentioning

confidence: 62%

“…11 and 12) were measured according to a previous publication [17] of the authors using thermocouples (type K; wire diameter 0.5 mm). In this earlier publication, the non-reinforced aluminum matrix of the present Al-MMC was dry turned.…”

Section: Experimental Designmentioning

confidence: 99%

“…In order to avoid this experimental effort for the new inhomogeneous Al-MMC material, an inverse identification during the regular turning process is used. A similar procedure has been applied successfully to detect the respective coefficients at the tool in [17]. The heat flow into the workpiece can be either approximated by the experimental method described in Sect.…”

Section: Fe Model Of the Workpiecementioning

confidence: 99%

“…The model of the tool has already been described by the authors in [17]. For a self-contained documentation, the main aspects are presented in the following.…”

Section: Fe Model Of the Toolmentioning

confidence: 99%

See 3 more Smart Citations

Identification of thermal effects on the diameter deviation of inhomogeneous aluminum metal matrix composite workpieces when dry turning

Schindler

Zimmermann

Aurich

et al. 2015

Prod. Eng. Res. Devel.

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The use of dry cutting is associated with considerable thermal loads on the machine tool, the tool and the workpiece because of the missing heat convection through the cutting fluid. These thermal loads cause thermal expansions of the components. The accuracy of machining is thus decreased. In recent years, particularly the thermal expansions of the workpiece and the tool attained significance due to the increased demands on the machining accuracy. Aluminum metal matrix composites (Al-MMCs) show a poor machinability due to the reinforcement of light metal alloys via hard and abrasive materials. Dry turning of such composites is therefore accompanied with high thermal workpiece and tool loads. In this paper, finite element models of the workpiece and the tool are used in order to calculate the temperature distribution and thus the thermally induced expansion of the workpiece and the tool when turning AL-MMC regarding the cutting condition used. The removal of material and the heat flow to the environment are considered. The required boundary conditions (e.g. the heat flow into the workpiece) for the simulations were determined using experimental results. A new evaluation method of experimental diameter measurement validates the numerically calculated diameter deviations and reveals a considerable effect of the thermal expansions of the workpiece and the tool on the accuracy of machining.

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Section: Experimental Designmentioning

confidence: 62%

Section: Experimental Designmentioning

confidence: 99%

Section: Fe Model Of the Workpiecementioning

confidence: 99%

“…The model of the tool has already been described by the authors in [17]. For a self-contained documentation, the main aspects are presented in the following.…”

Section: Fe Model Of the Toolmentioning

confidence: 99%

See 2 more Smart Citations

Identification of thermal effects on the diameter deviation of inhomogeneous aluminum metal matrix composite workpieces when dry turning

Schindler

Zimmermann

Aurich

et al. 2015

Prod. Eng. Res. Devel.

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show abstract

“…However, in order to perform a simulation over the entire time horizon, the trajectories of the induced heat loads are required. Therefore, the modeling of chip removing processes and the associated determination of the actual induced amount of heat into the workpiece to be considered is a highly active research topic, see e.g., [20,[24][25][26] and references therein. Since the chip removing process already requires a high accuracy model in order to identify the amount of heat entering the workpiece of interest, here we aim at reconstructing the heat inputs to the workpiece from observations of the temperature at accessible regions of the workpiece.…”

mentioning

confidence: 99%

Towards the identification of heat induction in chip removing processes via an optimal control approach

Lang

Saak

Benner

et al. 2015

Prod. Eng. Res. Devel.

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This paper presents a linear-quadratic regulator (LQR) approach for solving inverse heat conduction problems (IHCPs) arising in production processes like chip removing or drilling. The inaccessibility of the processed area does not allow the measuring of the induced temperature. Hence the reconstruction of the heat source based on given measurements at accessible regions becomes necessary. Therefore, a short insight into the standard treatment of an IHCP and the related LQR design is provided. The main challenge in applying LQR control to the IHCP is to solve the differential Riccati equation. Here, a model order reduction approach is used in order to reduce the system dimension. The numerical results will show the accuracy of the approach for a problem based on data given by practical measurements.In many production fields, a certain heat load is induced during a machining process, as e.g., drilling or milling procedures. These thermal loads affect the material properties and hence, cause deformations of the processed workpiece and the processing tool. Therefore, it is necessary to forecast the corresponding temperature field. However, in order to perform a simulation over the entire time horizon, the trajectories of the induced heat loads are required. Therefore, the modeling of chip removing processes and the associated determination of the actual induced amount of heat into the workpiece to be considered is a highly active research topic, see e.g., [20,[24][25][26] and references therein. Since the chip removing process already requires a high accuracy model in order to identify the amount of heat entering the workpiece of interest, here we aim at reconstructing the heat inputs to the workpiece from observations of the temperature at accessible regions of the workpiece. The procedure investigated here in fact tries to avoid the sophisticated modeling of the entire chip removing process. Instead of performing a direct simulation of the heat creation and transfer process, we solve an inverse heat conduction problem (IHCP) [18] for the induced heat. Still the reconstruction requires a good knowledge of the heat transfer coefficients used in our boundary conditions and thus can heavily benefit from the investigation of the forward process.

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Improvement of the Machining Accuracy in Dry Turning of Aluminum Metal Matrix Composites via Experiments and Finite Element Simulations

Zimmermann

Schindler

Aurich

et al. 2017

Lecture Notes in Production Engineering

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Finite Element Model to Calculate the Thermal Expansions of the Tool and the Workpiece in Dry Turning

Cited by 9 publications

References 12 publications

Identification of thermal effects on the diameter deviation of inhomogeneous aluminum metal matrix composite workpieces when dry turning

Identification of thermal effects on the diameter deviation of inhomogeneous aluminum metal matrix composite workpieces when dry turning

Towards the identification of heat induction in chip removing processes via an optimal control approach

Improvement of the Machining Accuracy in Dry Turning of Aluminum Metal Matrix Composites via Experiments and Finite Element Simulations

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