In this study the important aspects of cutting fluid distribution and the chip evacuation during micro twist deep-hole drilling are investigated using 3D multi-physics simulation methods. A coupled particle simulation is performed to analyze the chip transport by combining Smoothed Particle Hydrodynamics and the Discrete Element Method. Therefore, the transient transport of the chips is compared to a simulation scenario without chips. The coupled particle approach is capable to deal with free surfaces and fluid–solid interactions, that are subject to major topological changes over time. The chip positions resulting from the coupled particle simulation are used to carry out a Computational Fluid Dynamics simulation which considers the physical boundary conditions of the fluid and the process parameters to perform in-depth flow analyses. The results show good qualitative agreement between both simulation methods. Furthermore, the results show that large dead-zones with no fluid or almost zero fluid velocity exist in the flutes and that the chips there only experience a small evacuation force from the cutting fluid. The presented coupled approach of combining CFD and SPH–DEM simulation provide a significant support for future investigations to research the chip transport and to improve the tools and the process further.

在这项研究中，使用 3D 多物理场仿真方法研究了微扭曲深孔钻削过程中切削液分布和排屑的重要方面。通过结合平滑粒子流体动力学和离散元方法，执行耦合粒子模拟以分析切屑传输。因此，将芯片的瞬态传输与没有芯片的模拟场景进行比较。耦合粒子方法能够处理随时间发生重大拓扑变化的自由表面和流固相互作用。耦合粒子模拟产生的芯片位置用于执行计算流体动力学模拟，该模拟考虑流体的物理边界条件和工艺参数，以执行深入的流动分析。结果表明两种模拟方法之间具有良好的定性一致性。此外，结果表明，排屑槽中存在没有流体或几乎为零流体速度的大死区，并且那里的切屑仅从切削液中受到很小的排出力。所提出的结合 CFD 和 SPH-DEM 模拟的耦合方法为未来研究切屑传输和进一步改进工具和工艺提供了重要支持。