A novel approach to generate non-isotropic surfaces for numerical quantification of thermal contact conductance

The quantification of heat flow between machine tool components is of major importance for a precise thermal prediction of the entire system. A common coupling condition between individual components is the contact heat transfer coefficient connecting the temperature field with the corresponding heat transfer at the investigated interface. However, the majority of numerical and analytical approaches assume isotropic contact surface profiles and neglect distinct surface structures caused by the manufacturing process. This assumption causes inaccuracies in the modeling as isotropic surfaces lead to an overprediction in heat transfer. Hence, this paper presents a novel approach to generate surface structures for numerical calculations considering the used machining parameters. Predicted contact heat transfer coefficients of the old as well as the new generation approach are presented and compared to experimental results offering the basis for future comprehensive investigations considering multiple parameters and materials.