FEM-basiertes Softwaresystem für die effiziente 3D Gewindebohrsimulation und Werkzeugoptimierung mittels CFD-Simulation
Başlık çevirisi mevcut değil.
- Tez No: 597106
- Danışmanlar: DR. DIRK BIERMANN
- Tez Türü: Doktora
- Konular: Radyoloji ve Nükleer Tıp, Radiology and Nuclear Medicine
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 2016
- Dil: Almanca
- Üniversite: Technısche Unıversıtat Dortmund
- Enstitü: Yurtdışı Enstitü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: Belirtilmemiş.
Özet
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Özet (Çeviri)
Tapping is the most used process for manufacturing of internal threads and usually the last machining step when producing a workpiece. Asymmetrical tools, core holes with narrow tolerances, tool wear, or incorrectly chosen cutting speeds, cutting materials, cooling lubricants and chucks, quickly result in waste cut or, in the worst case, in tool breakage. In contrast to turning, drilling, or milling, the tapping process and its cutting tool is one of the least understood machining processes. To master a system and to optimize the tool using process parameters, it is necessary to have a basic understanding of machinability. Only by possessing the exact knowledge of cutting data, tool wear, tool life, cutting forces, chip formation and their correlations, a progressive processing of flexible machining systems and machine tools is possible. Due to a lack of basic research, the production of taps – the geometrical construction and their specification – depend on the practical knowledge of manufacturers, which is often passed on verbally and in strict confidence to the next generation. Although simulations based on the finite element method (FEM) are used in almost every manufacturing process, they cannot be used effectively for the tapping process. The high geometrical complexity of the tools with many cutting edges and different mesh situations represents significant challenges in the tapping process. For predicting the tool performance, one of the most important parameters of tapping is the torque. In contrast to other geometrically defined cutting edges, the cutting mechanism of tapping is completely different, since the dynamic cutting forces form over the whole chamfer length. The three-dimensional simulation of the tapping process presents great difficulties. Modelling and simulating all the tool variants over the whole chamfer length, to provide a basis for process optimization, would be too time-consuming. In this work, these challenges are met and an FEM-based software system is presented, which allows the three-dimensional simulation of tapping tools. The main focus is laid on the prediction of torque with practical computation times. At first, a general concept for this purpose will be described. On this basis, results of experimental and simulative investigations executed in metric tap series will be presented. Hereupon, methods and mathematical models to reduce the computing time, as well as a prediction method for the torque using other tool variants follow. The main methods used are the decomposition of the workpiece in partial segments and the interpolation and extrapolation from determined values for selected tool variants. Those methods are incorporated in the FEM-based software system. For the FE-simulation, the engineering software DEFORM 3D is employed. Therefore, an appropriate communicative interface is provided, which allows for the execution of pre- and postprocessor procedure steps as well as some solver options. For an interactive control, a user friendly graphical interface was created which considers the special conditions of the 3D-tapping process. The potential of the solution will be demonstrated by a dynamic system control. High performance taps are often equipped with internal cooling channels to increase productivity and reduce tool wear. The primary objective is to improve the supply of coolant to the cutting edge and secondly to ensure a universal tool design. Effective cooling and lubrication is a part of the process optimization and helps increasing process safety, while simultaneously decreasing production costs. Therefore, CFD analyses have been per-formed in this work, so that physical phenomena of the coolant lubrication flow in tapping processes could be investigated for the first time. The arrangement of the internal cooling channels was analyzed using CFD simulation and the tool was optimized accordingly. In doing so, an optimized tool was obtained on the one hand and on the other hand, the applicability as well as the reliability of the CFD approach have been validated.
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