4 Search Results for "Weber, Daniel"

Document
DOI: 10.4230/OASIcs.iPMVM.2020.5
Optimized Routine of Machining Distortion Characterization Based on Gaussian Surface Curvature

Authors: Destiny R. Garcia, Barbara S. Linke, and Rida T. Farouki

Published in: OASIcs, Volume 89, 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)

Abstract
Machining distortion presents a significant problem in products with high residual stresses from materials processing and re-equilibration after machining removes a large part of the material volume and is common in the aerospace industries. While many papers research on mechanisms of machining distortion, few papers report on the measurement, processing and characterization of distortion data. Oftentimes only line plot data is used to give a maximum distortion value. This paper proposes a method of measurement tool selection, measurement parameter selection, data processing through filtering and leveling, and use of Bézier Surfaces and Gaussian Curvature for distortion characterization. The method is demonstrated with three sample pieces of different pocket geometry from quenched aluminum. It is apparent that samples with machining distortion can have complex surface shapes, where Bézier Surfaces and Gaussian Curvature provide more information than the commonly used 2D line plot data.
Cite as

Destiny R. Garcia, Barbara S. Linke, and Rida T. Farouki. Optimized Routine of Machining Distortion Characterization Based on Gaussian Surface Curvature. In 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020). Open Access Series in Informatics (OASIcs), Volume 89, pp. 5:1-5:17, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@InProceedings{garcia_et_al:OASIcs.iPMVM.2020.5,
  author =	{Garcia, Destiny R. and Linke, Barbara S. and Farouki, Rida T.},
  title =	{{Optimized Routine of Machining Distortion Characterization Based on Gaussian Surface Curvature}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{5:1--5:17},
  series =	{Open Access Series in Informatics (OASIcs)},
  ISBN =	{978-3-95977-183-2},
  ISSN =	{2190-6807},
  year =	{2021},
  volume =	{89},
  editor =	{Garth, Christoph and Aurich, Jan C. and Linke, Barbara and M\"{u}ller, Ralf and Ravani, Bahram and Weber, Gunther H. and Kirsch, Benjamin},
  publisher =	{Schloss Dagstuhl -- Leibniz-Zentrum f{\"u}r Informatik},
  address =	{Dagstuhl, Germany},
  URL =		{https://drops-dev.dagstuhl.de/entities/document/10.4230/OASIcs.iPMVM.2020.5},
  URN =		{urn:nbn:de:0030-drops-137542},
  doi =		{10.4230/OASIcs.iPMVM.2020.5},
  annote =	{Keywords: Machining distortion, Metrology, Gaussian curvature}
}
Document
DOI: 10.4230/OASIcs.iPMVM.2020.7
Influence of Flank Face Structuring on Cooling, Tool Lifetime and Borehole Quality When Drilling Inconel 718: Physical Simulations and Experimental Validation

Authors: Daniel Müller, Benjamin Kirsch, and Jan C. Aurich

Published in: OASIcs, Volume 89, 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)

Abstract
When drilling difficult-to-cut materials such as Inconel 718, the drills are exposed to high thermomechanical loads. Due to the low thermal conductivity of the workpiece material, a large amount of the generated heat has to be dissipated by the metal working fluid (MWF). However, the cutting zone is located inside the workpiece, which makes it challenging to provide sufficient MWF to the cutting zone. To solve this, drills with internal cooling channels are commonly used. In this work, the influence of differently structured flank faces on cooling efficiency, tool life, process forces and borehole quality is investigated. The influence of the structures on the cooling was investigated by Computational-Fluid-Dynamics (CFD) simulations. These simulations allow a detailed analysis of the flow conditions inside the borehole and showed that the structuring improved flow conditions, especially near the thermally highly loaded main cutting edge. The improved flow conditions resulted in an extension of the tool life by up to 22 % compared to unstructured drills in experimental investigations.
Cite as

Daniel Müller, Benjamin Kirsch, and Jan C. Aurich. Influence of Flank Face Structuring on Cooling, Tool Lifetime and Borehole Quality When Drilling Inconel 718: Physical Simulations and Experimental Validation. In 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020). Open Access Series in Informatics (OASIcs), Volume 89, pp. 7:1-7:17, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@InProceedings{muller_et_al:OASIcs.iPMVM.2020.7,
  author =	{M\"{u}ller, Daniel and Kirsch, Benjamin and Aurich, Jan C.},
  title =	{{Influence of Flank Face Structuring on Cooling, Tool Lifetime and Borehole Quality When Drilling Inconel 718: Physical Simulations and Experimental Validation}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{7:1--7:17},
  series =	{Open Access Series in Informatics (OASIcs)},
  ISBN =	{978-3-95977-183-2},
  ISSN =	{2190-6807},
  year =	{2021},
  volume =	{89},
  editor =	{Garth, Christoph and Aurich, Jan C. and Linke, Barbara and M\"{u}ller, Ralf and Ravani, Bahram and Weber, Gunther H. and Kirsch, Benjamin},
  publisher =	{Schloss Dagstuhl -- Leibniz-Zentrum f{\"u}r Informatik},
  address =	{Dagstuhl, Germany},
  URL =		{https://drops-dev.dagstuhl.de/entities/document/10.4230/OASIcs.iPMVM.2020.7},
  URN =		{urn:nbn:de:0030-drops-137562},
  doi =		{10.4230/OASIcs.iPMVM.2020.7},
  annote =	{Keywords: drilling, cooling, CFD}
}
Document
DOI: 10.4230/OASIcs.iPMVM.2020.11
Finite Element Simulation Combination to Predict the Distortion of Thin Walled Milled Aluminum Workpieces as a Result of Machining Induced Residual Stresses

Authors: Daniel Weber, Benjamin Kirsch, Christopher R. Chighizola, Julianne E. Jonsson, Christopher R. D’Elia, Barbara S. Linke, Michael R. Hill, and Jan C. Aurich

Published in: OASIcs, Volume 89, 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)

Abstract
Machining induced residual stresses (MIRS) are a main driver for distortion of monolithic thin walled aluminum workpieces. A typical machining process for manufacturing such geometries for the aerospace industry is milling. In order to avoid high costs due to remanufacturing or part rejection, a simulation combination, consisting of two different finite element method (FEM) models, is developed to predict the part distortion due to MIRS. First, a 3D FEM cutting simulation is developed to predict the residual stresses due to machining. This simulation avoids cost intensive residual stress measurements. The milling process of the aluminum alloy AA7050-T7451 with a regular end mill is simulated. The simulation output, MIRS, forces and temperatures, is validated by face milling experiments on aluminum. The model takes mechanical dynamic effects, thermomechanical coupling, material properties and a damage law into account. Second, a subsequent finite element simulation, characterized by a static, linear elastic model, where the simulated MIRS from the cutting model are used as an input and the distortion of the workpiece is calculated, is presented. The predicted distortion is compared to an additional experiment, where a 1 mm thick wafer was removed at the milled surface of the aluminum workpiece. Furthermore, a thin walled component that represents a down scaled version of an aerospace component is manufactured and its distortion is analyzed. The results show that MIRS could be forecasted with moderate accuracy, which leads to the conclusion that the FEM cutting model needs to be improved in order to use the MIRS for a correct prediction of the distortion with the help of the linear elastic FEM model. The linear elastic model on the other hand is able to predict the part distortion with higher accuracy when using measured data instead of MIRS from the cutting simulation.
Cite as

Daniel Weber, Benjamin Kirsch, Christopher R. Chighizola, Julianne E. Jonsson, Christopher R. D’Elia, Barbara S. Linke, Michael R. Hill, and Jan C. Aurich. Finite Element Simulation Combination to Predict the Distortion of Thin Walled Milled Aluminum Workpieces as a Result of Machining Induced Residual Stresses. In 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020). Open Access Series in Informatics (OASIcs), Volume 89, pp. 11:1-11:21, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@InProceedings{weber_et_al:OASIcs.iPMVM.2020.11,
  author =	{Weber, Daniel and Kirsch, Benjamin and Chighizola, Christopher R. and Jonsson, Julianne E. and D’Elia, Christopher R. and Linke, Barbara S. and Hill, Michael R. and Aurich, Jan C.},
  title =	{{Finite Element Simulation Combination to Predict the Distortion of Thin Walled Milled Aluminum Workpieces as a Result of Machining Induced Residual Stresses}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{11:1--11:21},
  series =	{Open Access Series in Informatics (OASIcs)},
  ISBN =	{978-3-95977-183-2},
  ISSN =	{2190-6807},
  year =	{2021},
  volume =	{89},
  editor =	{Garth, Christoph and Aurich, Jan C. and Linke, Barbara and M\"{u}ller, Ralf and Ravani, Bahram and Weber, Gunther H. and Kirsch, Benjamin},
  publisher =	{Schloss Dagstuhl -- Leibniz-Zentrum f{\"u}r Informatik},
  address =	{Dagstuhl, Germany},
  URL =		{https://drops-dev.dagstuhl.de/entities/document/10.4230/OASIcs.iPMVM.2020.11},
  URN =		{urn:nbn:de:0030-drops-137604},
  doi =		{10.4230/OASIcs.iPMVM.2020.11},
  annote =	{Keywords: Machining induced residual stresses, distortion, Finite element method simulation}
}
Document
DOI: 10.4230/OASIcs.iPMVM.2020.16
Physical Modeling of Process Forces in Grinding

Authors: Praveen Sridhar, Daniel Mannherz, Raphael Bilz, Kristin M. de Payrebrune, Mahesh R.G. Prasad, and Juan Manuel Rodríguez Prieto

Published in: OASIcs, Volume 89, 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)

Abstract
This paper deals with material removal mechanisms in grinding by considering single grit-workpiece interactions. Individual investigations were performed both experimentally and using finite element simulations. Firstly, a comparison between the Johnson-Cooke material model and a Crystal Plasticity finite element method was performed with the help of micro-indentation experiments. Here the research question was answered if an anisotropic material model better describe the grinding process and process forces compared to an isotropic material model. Secondly, four discretization approaches were employed: pure Lagrangian (LAG), Arbitrary Lagrange Eulerian (ALE), Particle Finite Element Method (PFEM), and Smooth Particle Hydrodynamics (SPH), to simulate a micro-cutting operation of A2024 T351 aluminium. This study aims to compare the conventional approaches (LAG and ALE) to newer approaches (PFEM and SPH). The orthogonal cutting models were benchmarked against a micro-cutting experiment presented in literature, by comparing the obtained cutting and passive forces. The study was then extended to negative rake angles to study the effect on the discretization approaches for grinding. Thirdly, scratch experiments were investigated for a brittle material sodalime glass and A2024 T351 aluminium. Effects of the linear speed of the device, depth of cut, and conical tool angle were analyzed and tendencies are built. Finally, a realistic simulation of the manufacturing process of a grinding wheel was developed, starting with the raw material, compression, sintering, and dressing until the final grinding surface. As a result of the simulations, virtual grinding wheel topographies can be visualized and analyzed with regard to the output variables from grinding wheels such as bonding strength and static grain count. The individual research studies help in understanding the material removal mechanisms in a single grit scratch process as well as in the understanding of the overall grinding wheel topography. This in turn helps in the developing an overall physical force model for scratching/grinding to predict mechanical output parameters and hence reduce the need for experimentation.
Cite as

Praveen Sridhar, Daniel Mannherz, Raphael Bilz, Kristin M. de Payrebrune, Mahesh R.G. Prasad, and Juan Manuel Rodríguez Prieto. Physical Modeling of Process Forces in Grinding. In 2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020). Open Access Series in Informatics (OASIcs), Volume 89, pp. 16:1-16:20, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@InProceedings{sridhar_et_al:OASIcs.iPMVM.2020.16,
  author =	{Sridhar, Praveen and Mannherz, Daniel and Bilz, Raphael and de Payrebrune, Kristin M. and Prasad, Mahesh R.G. and Prieto, Juan Manuel Rodr{\'\i}guez},
  title =	{{Physical Modeling of Process Forces in Grinding}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{16:1--16:20},
  series =	{Open Access Series in Informatics (OASIcs)},
  ISBN =	{978-3-95977-183-2},
  ISSN =	{2190-6807},
  year =	{2021},
  volume =	{89},
  editor =	{Garth, Christoph and Aurich, Jan C. and Linke, Barbara and M\"{u}ller, Ralf and Ravani, Bahram and Weber, Gunther H. and Kirsch, Benjamin},
  publisher =	{Schloss Dagstuhl -- Leibniz-Zentrum f{\"u}r Informatik},
  address =	{Dagstuhl, Germany},
  URL =		{https://drops-dev.dagstuhl.de/entities/document/10.4230/OASIcs.iPMVM.2020.16},
  URN =		{urn:nbn:de:0030-drops-137651},
  doi =		{10.4230/OASIcs.iPMVM.2020.16},
  annote =	{Keywords: grinding, single grit approach, finite element method, smooth particle hydrodynamics, particle finite element method, scratch experiments, virtual grinding wheel model}
}
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