Abstract
Dry cutting ranks among the most significant developments within manufacturing technology. Compared to wet cutting, a major problem of dry machining is a stronger heat generation and thus, workpiece warming. This leads to thermoelastic workpiece deformation. Therefore, within this work a model is developed to predict and compensate the thermoelastic workpiece deformation. At first, friction behavior and heat transfer at the tool-chip interface in the orthogonal cutting process are experimentally investigated. Based on the fundamental investigations, a multiscale model for the dry turning process is developed. It contains two submodels, a mesoscopic FE-model for the chip formation and a macroscopic FE-model for the turning process. To validate the mesoscopic FE-model, experiments of orthogonal turning are performed and the temperature fields are measured. Hereby, the occurring heat flow into the workpiece is calculated by solving the inverse heat conduction problem. The macroscopic FE-model calculates the thermoelastic workpiece deformation based on heat inputs of the mesoscopic model. By means of the developed approach, minimization and compensation strategies are developed, applied and evaluated based on complex processing examples.
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