Efficiency Improvements of Machining Processes based on Novel Simulation Developments and Detailed Process Chain Analyses

An increasing prioritization of efficient processes in machining production can be observed in order to focus on the aspect of sustainability in addition to economic machining. In the work presented here, optimization potential in in the design and manufacture of tools and tool holders was identified based on novel simulation developments and detailed process and process chain analyses. For the efficient use of cooling lubricants in ejector deep hole drilling, the tool design could be adapted with the help of Smoothed Particle Hydrodynamics (SPH) simulations. Another aspect is the development of advanced particle-damped tool holders, the use of which can significantly increase process stability during turning and milling. In a detailed process chain analysis, the manufacturing route of cemented carbide tools was investigated to identify energy consuming process steps and form a basis to optimize the resource-efficient reprocessing of the tools.