Model-Based Representation of Thermo-energetic Effects in Cutting Tools and Part Clamping Devices

Abstract

In the representation of the machine tool’s manufacturing accuracy, involving thermo-elastic deformations in the tool and its chuck in the considerations is unavoidable, since a portion of the process heat is transmitted into the tool. Capture and estimation of the resultant thermo-elastic deformations is of significant importance for their compensation and correction. This paper presents the investigation and evaluation of thermo-elastic displacements in the tool-chuck system resulting from the heat flows from machining. The temperature and displacement measurements were conducted on a test bed with measuring equipment. In the first series of experiments, the transient heat conduction in the stationary tool and the chucking system, decoupled from the motor spindle, was captured. The chucks were compared in terms of their working principle. The identification of the thermal boundary and contact conditions was assisted by Finite Element models. The paper describes the experimental setups, the methods of measurement and the numerical models. An additional section discusses the determination of realistic heat sources generated in the machining process. Since measurement of these heat flows is either impossible or expensive and time-consuming, they are determined by numerical simulation of the machining process itself. This way, it can be determined to what extent the heat flows generated in the experiments by means of heating cartridge or induction correspond to those generated by the actual machining heat sources.