Multiscale Modeling of Thermoelastic Workpiece Deformation in Dry Cutting

In dry cutting an intensified heating of workpiece, tool and machine tool results in thermoelastic deformation which in turn causes dimensional and geometrical deviations of the machined parts. This paper presents a multiscale simulation method to calculate and compensate this effect. A chip formation model is used to compute the thermomechanical energy conversion and to determine the heat source of the cutting process on a mesoscopic model scale. This heat source is transferred on a macroscopic model that simulates the workpiece heating for a complete process sequence in order to analyze, reduce and compensate thermoelastic deformations. The multiscale simulation method is validated regarding the temperature and the resulting longitudinal workpiece deformation in dry turning of a gear shaft. However, the prediction of thermal deformation in radial dimensions needs additional validation with improved experiments and model features in future works.