Meshfree simulation of metal cutting: an updated Lagrangian approach with dynamic refinement

Afrasiabi, Mohamadreza; Roethlin, M.; Klippel, Hagen; Wegener, Konrad

doi:10.1016/j.ijmecsci.2019.06.045

Cited by 27 publications

(22 citation statements)

References 53 publications

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“…It is worth mentioning that all numerical simulations in this work are based on single-resolution SPH formulations; thus, a uniform constant mass is allocated to each computational node and the momentum equation (i.e., Equation (2)) does not require the utilization of mass scaling. An elaboration of this subject, as well as further details on the numerical stabilization procedure, can be found in [19,20]. This mechanical system is coupled with thermal effects by solving the heat conduction equation:…”

Section: Governing Equationsmentioning

confidence: 99%

“…At first glance, this discrepancy may not be within an acceptable range for some applications such as precision machining. Nevertheless, the community of SPH cutting simulations typically consider an average error of force prediction to verify their numerical results and not the maximum value, see, e.g., in [17,20,39].…”

Section: Force Prediction and Chip Shapementioning

confidence: 99%

“…Afrasiabi et al [19] employed this GPU-accelerated approach for inverse parameter identification and proposed a temperature-dependent coefficient of friction in SPH cutting models. Furthermore, a tailor-made framework for the multi-resolution SPH simulation of orthogonal cutting tests was published by [20]. It is worth mentioning that the computer codes utilized by these recent works are open source.…”

Section: Introductionmentioning

confidence: 99%

“…Although previous studies have demonstrated some excellent results in the capability of SPH to simulate metal cutting processes, none of them accounts for heat loss boundary conditions in their thermal model. More specifically, the issue with ignoring the heat transfer from the workpiece to the tool in SPH models (e.g., in [13,20]) was addressed by some recent works in [17,19]. However, the thermal modeling approach in these papers also suffers from two shortcomings: (1) Utilizing an inconsistent Laplacian operator that deteriorates the solution accuracy near the boundaries.…”

Section: Introductionmentioning

confidence: 99%

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Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

et al. 2021

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Smoothed Particle Hydrodynamics (SPH) is a mesh-free numerical method that can simulate metal cutting problems efficiently. The thermal modeling of such processes with SPH, nevertheless, is not straightforward. The difficulty is rooted in the computationally demanding procedures regarding convergence properties and boundary treatments, both known as SPH Grand Challenges. This paper, therefore, intends to rectify these issues in SPH cutting models by proposing two improvements: (1) Implementing a higher-order Laplacian formulation to solve the heat equation more accurately. (2) Introducing a more realistic thermal boundary condition using a robust surface detection algorithm. We employ the proposed framework to simulate an orthogonal cutting process and validate the numerical results against the available experimental measurements.

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Section: Governing Equationsmentioning

confidence: 99%

Section: Force Prediction and Chip Shapementioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

et al. 2021

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“…In [14], the authors reproduced the results of [12] by using yet another particle-based scheme. It is worth mentioning that the number of SPH developments in other fields of application is overwhelming, and numerous efforts have been made to model a variety of structural [15], CFD [16,17], and manufacturing simulations [18][19][20][21], to name a few. While a growing share of interest in meshfree simulations of laser processing can be noticed upon this literature survey, a comprehensive study of higher order SPH formulations for (3D) thermal modeling in laser-based manufacturing processes seems to be missing from the current state-of-the-art.…”

Section: Introductionmentioning

confidence: 99%

3D Thermal Simulation of a Laser Drilling Process with Meshfree Methods

Afrasiabi

Wegener

2020

JMMP

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Numerical simulation of laser drilling is rapidly gaining interest in academia and industry since this process remains one of the most important and widely-used technologies in modern manufacturing. Meshfree methods such as Smoothed Particle Hydrodynamics (SPH) have proven to be successful as a numerical tool for the computation of the heat transfer and material removal associated with a laser drilling problem. Nonetheless, the vast majority of recent developments incorporate an inconsistent SPH kernel into their thermal simulations. In this paper, several enhanced schemes are implemented to address this problem by solving the heat transfer more accurately. These meshfree schemes can provide a second-order accurate discretization of the Laplace operator and abolish the inconsistency issue of the standard SPH kernels. An efficient approach is additionally suggested to handle the associated boundary conditions, which relies on the idea of the color function and particle label. The implementation is initially validated by a 3D benchmark study and then applied for the first time to a laser drilling problem.

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Simulation of the ductile machining mode of silicon

Klippel

Süssmaier

Röthlin

et al. 2021

Int J Adv Manuf Technol

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Diamond wire sawing has been developed to reduce the cutting loss when cutting silicon wafers from ingots. The surface of silicon solar cells must be flawless in order to achieve the highest possible efficiency. However, the surface is damaged during sawing. The extent of the damage depends primarily on the material removal mode. Under certain conditions, the generally brittle material can be machined in ductile mode, whereby considerably fewer cracks occur in the surface than with brittle material removal. In the presented paper, a numerical model is developed in order to support the optimisation of the machining process regarding the transition between ductile and brittle material removal. The simulations are performed with an GPU-accelerated in-house developed code using mesh-free methods which easily handle large deformations while classic methods like FEM would require intensive remeshing. The Johnson-Cook flow stress model is implemented and used to evaluate the applicability of a model for ductile material behaviour in the transition zone between ductile and brittle removal mode. The simulation results are compared with results obtained from single grain scratch experiments using a real, non-idealised grain geometry as present in the diamond wire sawing process.

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Meshfree simulation of metal cutting: an updated Lagrangian approach with dynamic refinement

Cited by 27 publications

References 53 publications

Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

3D Thermal Simulation of a Laser Drilling Process with Meshfree Methods

Simulation of the ductile machining mode of silicon

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