Development of a Model for Calculating and Compensation of thermo-elastic Profile Defects and dimensional Errors in dry Machining

Thermographic images of cutting process WSA Thermographic images of the orthogonal cut on a broaching machine at successive points in time.

Dry machining is one of the most significant developments in manufacturing technology. A major problem is the higher warming of the work piece compared to wet machining, causing profile defects and dimensional errors. Up to the present day it is not possible to calculate these deformations based on the blank contour and the machining sequence. In the models published so far, the heat input into the components, such as the work piece ant the tool must be determined experimentally. The aim of the proposed research project is the development of a consistent calculation model for predetermining the thermally induced profile defects and dimensional errors and their compensation. The innovative approach of the project is using a FEM simulation of the chip formation process, to determine the heat input (heat source term) into the work piece as a function of the machining parameters. The determined heat source term is used for further FEM simulations to calculate the thermally induced profile defects and dimensional errors. Finally the calculation model offers the opportunity to minimize these deformations by a specific variation of the cutting parameters and the machining sequence without the need to determine the heat input in advance by any experiments.

Project details

Project duration

09/2010 – 08/2016

Funded by




  • Two-Color-Pyrometer (Fire 2.0)
  • High-speed IR camera (Infratec, ImageIR 5325, MWIR), 50mm-objectiv und microscope optics 30μm/Pixel
  • Hochgeschwindigkeits-IR-Kamera (Flir/Cedip, JadeIII, LWIR), 50mm-objectiv und microscope optics 13μm/Pixel
  • Black body (Temperatures 20-125C)
  • Black body cavity (Temperatures up to 1200C)
  • Servo-hydraulic testing machine