Hybrid SPH-FEM solver for metal cutting simulations on the GPU including thermal contact modeling

Zhang, Nanyuan; Klippel, Hagen; Afrasiabi, Mohamadreza; Röthlin, Matthias; Kuffa, Michal; Bambach, Markus; Wegener, Konrad

doi:10.1016/j.cirpj.2022.12.012

Cited by 14 publications

(2 citation statements)

References 59 publications

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“…19: Schematic of hybrid SPH-FEM simulation model with a rake face modified tool with a Täschli with a distance to the cutting edge l c1 ′ of 34.2 µm. of governing equations, contact algorithms, and GPU implementation, readers are referred to the original works [19], [2], [20].…”

Section: Modeling Of Orthogonal Cutting Simulationsmentioning

confidence: 99%

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Kneubühler,

Zhang,

Haudenschild

et al. 2024

Preprint

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Finishing machining of Ti6Al4V, known for its high strength and heat conduction resistance, demands optimisation to achieve high-quality end products. This study explores modifying the chip contact length on the rake face and altering the flank face with a cavity to minimise process forces and temperatures, while maintaining cutting edge integrity. The research validates the manufacturability of laser-modified tools through ultra-short pulsed laser ablation, indicating potential for industrial scale-up. Extensive experimental evaluations under dry conditions assess the impact of tool modifications at various feed rates for planing and turning. Significant reductions in process forces and temperatures were observed with rake face modifications, particularly at a cavity distance of approximately \qty{34}{\micro\meter}. Ideal performance was noted for feed rates between \qtyrange[range-units=single]{0.035}{0.045}{\milli\meter} for planing and \qtyrange[range-units=single]{0.040}{0.045}{\milli\meter}/rev for turning. Smoothed Particle Hydrodynamics (SPH) simulations employing a Johnson-Cook material model were used to analyse chip formation and to predict the process forces. These simulations revealed a clear change in the chip formation and lower process forces and temperatures. The SPH results closely matched experimental outcomes, with a discrepancy of less than \qty{7}{\percent} in cutting forces for both tool types, although feed forces were underestimated by about \qty{50}{\percent}. The effect o the tool modification is reflected accurately at the specified feeds.

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Section: Modeling Of Orthogonal Cutting Simulationsmentioning

confidence: 99%

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Kneubühler,

Zhang,

Haudenschild

et al. 2024

Preprint

View full text Add to dashboard Cite

show abstract

“…SŁOWA KLUCZOWE: modelowanie bezsiatkowe, symulacja numeryczna, obróbka skrawaniem Wprowadzenie W ostatniej dekadzie obserwuje się wzrost zainteresowania zastosowaniem tzw. bezsiatkowego modelowania i symulacji procesów obróbki ubytkowej przyrostowej i plastycznej, co jest następstwem rozwoju metod modelowania graficznego z użyciem kart graficznych, czyli na jednym procesorze (CPU), i solwerów graficznych, czyli na wielu procesorach (GPU) [1][2][3][4]. W poprzednim artykule [1] opisano zastosowanie metod MD (molecular dynamics) i SPH (smoothed particle hydrodynamics) w hybrydowym modelowaniu procesu skrawania, łączącym tradycyjne modelowanie siatkowe (FEM/MES, ale głównie metodę hybrydową FEM Eulerian-Lagrangian -ALE), które jest jednym ze sposobów realizacji tzw.…”

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Progress in modelling and simulation of the machining process – part II: Mesh-free modelling and simulation

Grzesik

2024

Mechanik

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In this paper some rules of mesh-free/meshless modelling and numerical simulations of fundamental physical phenomena associated with the machining process, including mechanisms of plastic deformation, chip formation and interfacial friction are overviewed. Some representative examples of the mesh-free modelling application to material removal processes at different scales, i.e.: machining processes, water jet-assisted processes, additive machining processes and simulation of micromachining processes using predominantly SPH (smoothed particle hydrodynamics) method are given.

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Enhancing orthogonal finishing machining of Ti6Al4V with laser-ablated tool geometry modifications

Kneubühler,

Zhang,

Haudenschild

et al. 2024

Int J Adv Manuf Technol

View full text Add to dashboard Cite

Finishing machining of Ti6Al4V, known for its high strength and heat conduction resistance, demands optimisation to achieve high-quality end products. This study explores modifying the chip contact length on the rake face and altering the flank face with a cavity to minimise process forces and temperatures while maintaining cutting edge integrity. The research validates the manufacturability of ultra-short pulsed laser-ablated tool geometry modifications, indicating potential for industrial scale-up. Extensive experimental evaluations under dry conditions assess the impact of tool modifications at various feed rates for planing and turning. Significant reductions in process forces and temperatures were observed with rake face modifications, particularly at a cavity distance of approximately 34 µm. Ideal performance was noted for feed rates between 0.035 and 0.045 mm for planing and 0.040 to 0.045 mm/rev for turning. Smoothed Particle Hydrodynamics (SPH) simulations employing a Johnson-Cook material model were used to analyse chip formation and to predict the process forces. These simulations revealed a clear change in the chip formation and lower process forces and temperatures. The SPH results closely matched experimental outcomes, with a discrepancy of less than 7 % in cutting forces for both tool types, although feed forces were underestimated by about 50 %. The effect of the tool modification is reflected accurately at the respective feeds.

show abstract

Hybrid SPH-FEM solver for metal cutting simulations on the GPU including thermal contact modeling

Cited by 14 publications

References 59 publications

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Enhancing Orthogonal Finishing Machining of Ti6Al4V with Laser Modified Tools

Progress in modelling and simulation of the machining process – part II: Mesh-free modelling and simulation

Enhancing orthogonal finishing machining of Ti6Al4V with laser-ablated tool geometry modifications

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