Browsing by Author "Biermann, Dirk"

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Open Access
Flow visualisation and evaluation studies on metalworking fluid applications in manufacturing processes : methods and results
(2023) Fritsching, Udo; Buss, Lizoel; Tonn, Teresa; Schumski, Lukas; Gakovi, Jurgen; Hatscher, Johnson David; Sölter, Jens; Avila, Kerstin; Karpuschewski, Bernhard; Gerken, Julian Frederic; Wolf, Tobias; Biermann, Dirk; Menze, Christian; Möhring, Hans-Christian; Tchoupe, Elio; Heidemanns, Lukas; Herrig, Tim; Klink, Andreas; Nabbout, Kaissar; Sommerfeld, Martin; Luther, Fabian; Schaarschmidt, Ingo; Schubert, Andreas; Richter, Markus
Metalworking operations rely on the successful application of metalworking fluids (MWFs) for effective and efficient operation. Processes such as grinding or drilling often require the use of MWFs for cooling, lubrication, and chip removal. Electrochemical machining processes require electrolyte flow to operate. However, in those machining operations, a fundamental understanding of the mode of action of MWF is lacking due to the unknown flow dynamics and its interaction with the material removal during the process. Important information on the behaviour of MWFs during machining can be obtained from specific experimental flow visualisation studies. In this paper, promising flow visualisation analysis techniques applied to exemplary machining processes (grinding, sawing, drilling, and electrochemical machining) are presented and discussed. Shadowgraph imaging and flow measurements, e.g., particle image velocimetry, allow the identification of typical flow and MWF operating regimes in the different machining processes. Based on the identification of these regimes, efficient machining parameters and MWF applications can be derived. In addition, detailed experimental analyses of MWFs provide essential data for the input and validation of model development and numerical simulations within the Priority Programme SPP 2231 FluSimPro.
Open Access
Geometry modifications of single-lip drills to improve cutting fluid flow
(2022) Baumann, Andreas; Oezkaya, Ekrem; Biermann, Dirk; Eberhard, Peter
For single-lip drills with small diameters, the cutting fluid is supplied through a kidney-shaped cooling channel inside the tool. In addition to reducing friction, the cutting fluid is also important for the dissipation of heat at the cutting edge and for the chip removal. However, in previous investigations of single-lip drills, it was observed that the fluid remains on the back side of the cutting edge, and accordingly, the cutting edge is insufficiently cooled. In this paper, a simulation-based investigation of an introduced additional drainage flute and flank surface modifications is carried out using smoothed particle hydrodynamics as well as computational fluid dynamics. It is determined that the additionally introduced drainages lead to a slightly changed flow situation, but a significant flow behind the cutting edge and into the drainage flute cannot be achieved due to reasons explained in this paper. Accordingly, not even a much larger drainage flute with unwanted side-effect of a decrease tool strength is able to archive a significant improvement of the flow around the cutting edge. Therefore, major changes to the cooling channel, like the use of two separate channels, the modification of their positions, or modified flank surfaces, are necessary in order to achieve an improvement in lubrication of the cutting edge and heat dissipation.
Open Access
Modeling and mitigation of vortex formation in ejector deep hole drilling with smoothed particle hydrodynamics
(2024) Baumann, Andreas; Gerken, Julian Frederic; Sollich, Daniel; Rupasinghe, Nuwan; Biermann, Dirk; Eberhard, Peter
Ejector deep hole drilling achieves high-quality boreholes in production processes. High feed rates are applied to ensure a high productivity level, requiring reliable chip removal from the cutting zone for a stable process. Therefore, a constant metalworking fluid flow under high volume flow rates or high pressure is required. Experimental results show a vortex formation at the outer cutting edge. This vortex can lead to delayed chip removal from the cutting zone, and ultimately, it can lead to chip clogging and result in drill breakage due to increased torque. This paper investigates modified drill head designs using the smoothed particle hydrodynamics method. The investigated modifications include various designs of the chip mouth covering. Besides graphical analysis based on flow visualizations, flow meters are placed at the tool’s head to evaluate the impact of the modifications on the flow rate and possible increased resistance and relocation of the fluid flow from the outer cutting edge to other parts of the tool. The simulation results for the reference design show the experimentally observed vortex formation, validating the simulation model. By adding the tool’s rotation in the SPH simulation, which is not included in the experiments for observation reasons, the vortex formation is positively influenced. In addition, some designs show promising results to further mitigate the vortex formation while maintaining a sufficient fluid flow around the cutting edges.