Modelling, Simulation and Compensation of Thermomechanically Induced Deviations in Deep-Hole Drilling with Minimum Quantity Lubrication

Biermann, D.1, a; Blum, H.2, b; Iovkov, I.1, c; Rademacher, A.2, d; Rosin, K.2, e; Suttmeier, F.-T.3, f

Institut für Spanende Fertigung, Technische Universität Dortmund, Baroper Str. 303, 44227 Dortmund
Lehrstuhl für Wissenschaftliches Rechnen (LS X), Technische Universität Dortmund, Vogelpothsweg 87, 44227 Dortmund
Arbeitsgruppe Wissenschaftliches Rechnen, Universität Siegen, Emmy-Noether-Campus, Walter-Flex-Str. 3, 57068 Siegen

a); b); c); d); e); f)


This chapter summarises interdisciplinary research work on deep-hole drilling of aluminium casting using twist drills and minimum quantity lubrication (MQL). The high thermal conductivity of the workpiece material, the low cooling performance of MQL and the long main time of the process lead to a significant thermal load onto the workpiece. The thermal distortion of the machined component causes a systematic deflection of the long drilling tool and thus a high straightness deviation of the produced bore. Based on extensive technological investigations with a focus on the heat input into the workpiece a reliable simulation-based prediction of the thermomechanical distortion and the resulting bore deviations is presented. Thereby a finite element (FE)-model of the workpiece was coupled with a simple analytic representation of the deep-hole drilling tool. Using the fictitious domain method, adaptive techniques, and massive parallelisation, the FE-simulation is most efficiently realised. In order to compensate the occurring deviations, a novel approach based on radial tool path adjustment was developed, which allows for the drilling direction to be controlled during the process. The sophisticated simulations enable the determination of the optimal NC-path for the deep-hole drilling tool, which is not possible based on experiments. The validation results show a great potential of the developed methods for the simulation-based minimisation of the thermomechanically induced straightness deviation in deep-hole drilling.


In: Biermann D., Hollmann F. (eds) Thermal Effects in Complex Machining Processes. Lecture Notes in Production Engineering. Springer, Cham, (2018), S. 181-218, doi: 10.1007/978-3-319-57120-1_10