Simulating the Heat Distortiion of a Cast Iron Brake Disc during Dry Machining

The application of MQL or dry machining in mass production becomes more and more accepted. Dry (MQL) machining is a very efficient solution to reduce the usage of cutting fluids and represents an effective measure for an environmental friendly production. However, these techniques do not benefit any more from the stabilization in temperature obtained with cutting fluids. More important and more heterogeneous increases of the temperature are observed. This leads to distortions of the work piece during machining which are necessary to be taken into account to maintain the geometrical quality of the manufactured surfaces. In this paper, we present a strategy to handle these thermal induced distortions in an industrial context. This strategy couples finite element thermo-elastic simulations and temperature measurements of the work piece. In a first section, we describe a method to identify machined characteristics sensible to part temperature at loading. This method takes into account standard deviation of the process. A solution to adapt tool trajectories with a temperature measurement is proposed. Second part deals with distortions of the part during manufacturing. A method is proposed to simulate distortions along machining. These FEM simulations allow to identify impact of a machining on next operations. An application of the proposed approach for the machining of a cast iron brake disc is presented. Simulations are compared to measurements made in a dry manufacturing line