Simulation and Multi-Objective Optimization of Thermal Distortions for Milling Processes

Abstract

During a machining process, the produced heat results in thermomechanical deformation of the workpiece and thus an incorrect material removal by the cutting tool, which may exceed given tolerances. We present a numerical model based on an adaptive finite element simulation for thermomechanics, which takes into account both the approximation of the temperature field as well as the approximation of the time dependent domain. Control of the milling parameters and tool path can be used to minimize the final shape deviation. A multi-objective approach can try to additionally reduce the tool wear. We present results from a simulation-based optimization approach for a simplified workpiece.