TY - JOUR

T1 - Modelling of sawing processes with internal coolant supply

AU - Menze, Christian

AU - Reeber, Tim

AU - Möhring, Hans Christian

AU - Stegmann, Jan

AU - Kabelac, Stephan

N1 - Funding Information: The authors appreciate the funding by the German Research Foundation (DFG) – project number 439925537.

PY - 2022/4

Y1 - 2022/4

N2 - The circular sawing process is an important step in the preparation of intermediate parts in industrial manufacturing. A particular characteristic of the sawing process is that the cutting process takes place in a chip space in the closed cutting gap. As part of an ongoing research project, the application of an internal coolant supply for the sawing process is being investigated. The long-term goal of the project is to develop a highly efficient and resource-saving circular sawing process through optimised internal coolant supply. Since the cutting zone during sawing with a fluid is difficult to access using measurement equipment, simulation is used in addition to experimental investigations to examine the thermo-mechanical and thermo-fluid processes in the internal cutting gap. This paper presents a first proof of concept of a FEM - model for sawing with internal coolant supply using the CEL approach. The aim was to show the opportunities and limitations of the current model with respect to the research project. The validation of orthogonal cutting of the material AISI 1045 with the CEL approach showed a 15% deviation in the cutting force and a 17% deviation in the chip compression. The state of the interaction of the fluid with the hot chip showed a physically imperfect behaviour due to insufficient models of the complex thermo-fluid heat transfers. However, the model can be used in its first design to investigate the mechanical interaction of an internal coolant supply between chip and fluid and serves as a starting point for the simulative investigation of the complex thermo-mechanical and thermo-fluid processes during sawing, considering a cooling fluid.

AB - The circular sawing process is an important step in the preparation of intermediate parts in industrial manufacturing. A particular characteristic of the sawing process is that the cutting process takes place in a chip space in the closed cutting gap. As part of an ongoing research project, the application of an internal coolant supply for the sawing process is being investigated. The long-term goal of the project is to develop a highly efficient and resource-saving circular sawing process through optimised internal coolant supply. Since the cutting zone during sawing with a fluid is difficult to access using measurement equipment, simulation is used in addition to experimental investigations to examine the thermo-mechanical and thermo-fluid processes in the internal cutting gap. This paper presents a first proof of concept of a FEM - model for sawing with internal coolant supply using the CEL approach. The aim was to show the opportunities and limitations of the current model with respect to the research project. The validation of orthogonal cutting of the material AISI 1045 with the CEL approach showed a 15% deviation in the cutting force and a 17% deviation in the chip compression. The state of the interaction of the fluid with the hot chip showed a physically imperfect behaviour due to insufficient models of the complex thermo-fluid heat transfers. However, the model can be used in its first design to investigate the mechanical interaction of an internal coolant supply between chip and fluid and serves as a starting point for the simulative investigation of the complex thermo-mechanical and thermo-fluid processes during sawing, considering a cooling fluid.

KW - Cooling

KW - Cutting

KW - Simulation

UR - http://www.scopus.com/inward/record.url?scp=85134005162&partnerID=8YFLogxK

U2 - 10.1016/j.mfglet.2022.04.006

DO - 10.1016/j.mfglet.2022.04.006

M3 - Article

AN - SCOPUS:85134005162

VL - 32

SP - 92

EP - 95

JO - Manufacturing Letters

JF - Manufacturing Letters

SN - 2213-8463

ER -