Simulation and Multi-Objective Optimization of Thermal Distortions for Milling Processes
During a machining process, the produced heat results in thermomechanical deformation of the workpiece and thus an incorrect material removal by the cutting tool, which may exceed given tolerances.
We present a numerical model based on an adaptive finite element simulation for thermomechanics, which takes into account both the approximation of the temperature field as well as the approximation of the time dependent domain.
Control of the milling parameters and tool path can be used to minimize the final shape deviation. A multi-objective approach can try to additionally reduce the tool wear. We present results from a simulation-based optimization approach for a simplified workpiece.
We thank Dietmar Hömberg for organizing MS26 “Maths for the Digital Factory” where we could report about the subject.
The presented results have been obtained within the research project “Thermomechanical Deformation of Complex Workpieces in Drilling and Milling Processes” (DE 447/90-3, MA 1657/21-3) within the DFG Priority Program 1480 “Modeling, Simulation and Compensation of Thermal Effects for Complex Machining Processes” as well as in the DAAD-CONACYT PROALMEX project “Numerical Simulation and Optimization of Time Dependent Processes in Engineering and Materials Science”. The authors would like to thank DFG, DAAD, and CONACYT for the financial and organizational support of the projects. Furthermore, we thank our project partners from ZeTeM Bremen and IFW Hannover for cooperation.
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