Thermo-energetic design of machine tools

A systemic approach to solve the conflict between power efficiency, accuracy and productivity demonstrated at the example of machining production

In the field of precision machining of metals, the general conditions and social goals – as the preservation of resources and the improvement of the power-efficiency in production engineering, the needs of flexible manufacturing, as well as the continuous demand of a steady increase in productivity lead to a conflict of aims between energy efficiency, accuracy, and productivity.
The scientific objective of the research program in SFB/TR-96 is to solve this basic conflict by exploring and implementing solutions, which allow high-precision machining while still meeting future requirements of power-efficient production i.e. allow for shut-down measures without decreasing the accuracy of the machine.
The findings of this research project will effectively minimize the impacts of thermo-elastic deformations on the Tool Centre Point (TCP) by data- or rather model-based, in-process correction of deformations integrated into the control of the machine tool. Another option to efficiently reduce thermo-elastic deformations is expected from the compensation for thermal impacts by adjusting the heat flow or the temperature distribution within the machine structure.
Therefore, SFB/TR-96 is establishing basic concepts, procedures, algorithms, calculation tools, and components, which have to prove themselves under strong variations of the process requirements, as well as of the application and work environment conditions.

Main objectives
The general aim of SFB is the exploration and implementation of effective correction and compensation solutions, which enable high accuracy machining and energy-efficient manufacturing at the same time.

Partial goals:

  • Development of modeling basics for calculating thermo-elastic deformations and the causative heat flows.
  • Ensuring correct parameters for the relevant heat sources and heat transfer members as well as exploring parameter identification procedures.
  • Development and demonstration of solutions of control-integrated correction.
  • Development of methods to compensate for thermo-elastic effects by stabilizing the temperature field and by reducing or distributing the heat input into the machine structure more uniformly.
  • Finding new basic methods for the measurement of thermo-elastic deviations within selected structural areas of machine tools.
  • Technical and economical evaluation of the developed solutions regarding their effects on the quality of the product, the productive capacity, the energy consumption, and their costs.