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Priority Programme 2231: Efficient cooling, lubrication and transportation – coupled mechanical and fluid-dynamical simulation methods for efficient production processes (FLUSIMPRO)

Integral coupled simulation of fluid dynamics of the metal cutting fluid and the cutting process in vibrationn assisted drilling - ViBohr

Fluids are used as cooling lubricants (coolants) in almost all production processes. Along with the machine technology used, the process parameters, the tools and the materials to be machined, they are among the elementary process influencing variables. A detailed understanding of the mechanisms of action of coolants, especially when machining demanding materials, is therefore essential for their targeted and efficient use. However, the relevant length and time scales can only be insufficiently analysed with experimental methods, so that the development of new methods for process simulation is necessary in order to be able to map the complex procedures in detail when using fluids in production processes and to exploit their potential in industrial applications. From this problem, the overarching objective of SPP 2231 is to scientifically develop the necessary fundamentals through interdisciplinary cooperation and to realise coupled mechanical and fluid-dynamic simulation methods. The focus is exclusively on production processes in which the coolant takes on cooling, lubricating and transporting functions, for example of chips, charge carriers, abrasives or reaction products.

Leibniz-IWT is contributing to the field with the sub-project "Integral coupled simulation of fluid dynamics of the metal cutting fluid and the cutting process in vibrationn assisted drilling - ViBohr". In this project, the fluid-structure interactions during vibration-assisted drilling coupled with minimum quantity lubrication (MQL) are numerically investigated.

The overall objective of the sub-project ViBohr within the priority programme 2231 FluSimPro is to achieve process optimisation by means of a coupled ViBohr process simulation model on the basis of a fundamental understanding of the effect of the MQL flow and the wetting behaviour on the chip formation and chip transport mechanisms as well as the associated heat transport during vibration-assisted drilling.

The constant axial vibration movement of the drill leads to the formation of small chips compared to the previously long spiral chips typically produced in conventional drilling processes. This results in lower thermomechanical stress on the drilling tool as well as drill holes with more uniform dimensions and higher surface quality.

More information on the priority programme.