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Documents authored by Kirsch, Benjamin

Document
Complete Volume
DOI: 10.4230/OASIcs.iPMVM.2020
OASIcs, Volume 89, iPMVM 2020, Complete Volume

Authors: Christoph Garth, Jan C. Aurich, Barbara Linke, Ralf Müller, Bahram Ravani, Gunther H. Weber, and Benjamin Kirsch

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

Abstract
OASIcs, Volume 89, iPMVM 2020, Complete Volume
Cite as

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. 1-364, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@Proceedings{garth_et_al:OASIcs.iPMVM.2020,
  title =	{{OASIcs, Volume 89, iPMVM 2020, Complete Volume}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{1--364},
  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.dagstuhl.de/entities/document/10.4230/OASIcs.iPMVM.2020},
  URN =		{urn:nbn:de:0030-drops-137486},
  doi =		{10.4230/OASIcs.iPMVM.2020},
  annote =	{Keywords: OASIcs, Volume 89, iPMVM 2020, Complete Volume}
}
Document
Front Matter
DOI: 10.4230/OASIcs.iPMVM.2020.0
Front Matter, Table of Contents, Preface, Conference Organization

Authors: Christoph Garth, Jan C. Aurich, Barbara Linke, Ralf Müller, Bahram Ravani, Gunther H. Weber, and Benjamin Kirsch

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

Abstract
Front Matter, Table of Contents, Preface, Conference Organization
Cite as

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. 0:i-0:xii, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@InProceedings{garth_et_al:OASIcs.iPMVM.2020.0,
  author =	{Garth, Christoph and Aurich, Jan C. and Linke, Barbara and M\"{u}ller, Ralf and Ravani, Bahram and Weber, Gunther H. and Kirsch, Benjamin},
  title =	{{Front Matter, Table of Contents, Preface, Conference Organization}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{0:i--0:xii},
  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.dagstuhl.de/entities/document/10.4230/OASIcs.iPMVM.2020.0},
  URN =		{urn:nbn:de:0030-drops-137497},
  doi =		{10.4230/OASIcs.iPMVM.2020.0},
  annote =	{Keywords: Front Matter, Table of Contents, Preface, Conference Organization}
}
Document
DOI: 10.4230/OASIcs.iPMVM.2020.2
Physical Modeling of Process-Machine-Interactions in Micro Machining

Authors: Andreas Lange, Benjamin Kirsch, Marius Heintz, 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
Increasing demands for smaller and smarter devices in a variety of applications requires the investigation of process-machine-interactions in micro manufacturing to ensure process results that guarantee part functionality. One approach is the use of simulation-based physical models. In this contribution, methods for the physical modeling of high-precision air bearing and magnetic bearing spindles are presented in addition to a kinematic model of the micro milling process. Both models are superimposed in order to carry out investigations of the slot bottom surface roughness in micro end milling. The results show that process-machine-interactions in micro manufacturing can be modeled by the superposition of a physical model of the machine tool spindle taking cutting forces into consideration and a purely kinematic model of the machining process, providing the necessary tools for a variety of further investigations into process-machine-interactions in micro manufacturing.
Cite as

Andreas Lange, Benjamin Kirsch, Marius Heintz, and Jan C. Aurich. Physical Modeling of Process-Machine-Interactions in Micro Machining. 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. 2:1-2:20, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@InProceedings{lange_et_al:OASIcs.iPMVM.2020.2,
  author =	{Lange, Andreas and Kirsch, Benjamin and Heintz, Marius and Aurich, Jan C.},
  title =	{{Physical Modeling of Process-Machine-Interactions in Micro Machining}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{2:1--2:20},
  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.dagstuhl.de/entities/document/10.4230/OASIcs.iPMVM.2020.2},
  URN =		{urn:nbn:de:0030-drops-137512},
  doi =		{10.4230/OASIcs.iPMVM.2020.2},
  annote =	{Keywords: multiphysics, air bearing, magnetic bearing, surface roughness modeling, micro milling}
}
Document
DOI: 10.4230/OASIcs.iPMVM.2020.3
Simulation and Application of a Piezo-Driven System Enabling Vibration-Assisted Micro Milling

Authors: Sebastian Greco, Katja Klauer, 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
The ongoing miniaturization of components and the functionalization of surfaces necessitates the improvement of micro machining processes and to increase their efficiency. One method to increase the machining efficiency is reducing the process forces and tool wear, which is achieved by the implementation of vibration-assisted cutting in conventional machining processes. In vibration-assisted cutting, the conventional cutting movement is superimposed by a vibration with defined frequency. By using vibration-assisted cutting technologies, besides increased efficiency, a wider range of materials can be machined. In this paper, vibration-assisted cutting is transferred to micro machining. For this purpose, the design, simulation and application of an easy to integrate system that enables vibration-assisted cutting for micro machining processes is described. The setup was tested using a micro milling process. Two orientations between feed direction and vibration direction were investigated. Frequencies up to 15 kHz were examined, the machined material was brass (CuZn39Pb2). The effect of the superimposed vibration was analysed on the basis of process force, surface roughness, burr formation and slot bottom and was compared with the process results of micro milling without vibration-assistance. A decrease in process forces of up to 63 % was observed during vibration-assisted micro milling.
Cite as

Sebastian Greco, Katja Klauer, Benjamin Kirsch, and Jan C. Aurich. Simulation and Application of a Piezo-Driven System Enabling Vibration-Assisted Micro Milling. 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. 3:1-3:18, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@InProceedings{greco_et_al:OASIcs.iPMVM.2020.3,
  author =	{Greco, Sebastian and Klauer, Katja and Kirsch, Benjamin and Aurich, Jan C.},
  title =	{{Simulation and Application of a Piezo-Driven System Enabling Vibration-Assisted Micro Milling}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{3:1--3:18},
  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.dagstuhl.de/entities/document/10.4230/OASIcs.iPMVM.2020.3},
  URN =		{urn:nbn:de:0030-drops-137523},
  doi =		{10.4230/OASIcs.iPMVM.2020.3},
  annote =	{Keywords: micro machining, micro milling, vibration-assisted cutting, Finite Element Analysis, surface roughness}
}
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.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.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.2020.17
Molecular Simulation Study on the Influence of the Scratching Velocity on Nanoscopic Contact Processes

Authors: Sebastian Schmitt, Simon Stephan, Benjamin Kirsch, Jan C. Aurich, Eberhard Kerscher, Herbert M. Urbassek, and Hans Hasse

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

Abstract
The influence of the scratching velocity on mechanical and thermal properties of a nanoscopic contact process was studied by molecular dynamics simulations. Simulations with different scratching velocities were conducted in dry and lubricated systems. The contact process consisted of a lateral scratching of a spherical indenter on a planar substrate. All molecular interactions were described by the Lennard-Jones truncated and shifted potential. The forces on the indenter, the coefficient of friction and the work done by the indenter as well as the power applied on the indenter were sampled. Furthermore, an analysis of thermal properties was conducted: The change of the energy of the substrate, the indenter and the fluid was evaluated and the local temperature field was determined. The forces, the coefficient of friction and the work done by the indenter show practically no influence of the scratching velocity. The work done by the indenter was found to be the same for all velocities. As a consequence, the power supplied to the system depends linearly on the scratching velocity, which affects the temperature of the contact zone. As expected, the presence of a lubricant reduces the temperature of the substrate in the vicinity of the contact.
Cite as

Sebastian Schmitt, Simon Stephan, Benjamin Kirsch, Jan C. Aurich, Eberhard Kerscher, Herbert M. Urbassek, and Hans Hasse. Molecular Simulation Study on the Influence of the Scratching Velocity on Nanoscopic Contact Processes. 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. 17:1-17:16, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@InProceedings{schmitt_et_al:OASIcs.iPMVM.2020.17,
  author =	{Schmitt, Sebastian and Stephan, Simon and Kirsch, Benjamin and Aurich, Jan C. and Kerscher, Eberhard and Urbassek, Herbert M. and Hasse, Hans},
  title =	{{Molecular Simulation Study on the Influence of the Scratching Velocity on Nanoscopic Contact Processes}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{17:1--17:16},
  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.dagstuhl.de/entities/document/10.4230/OASIcs.iPMVM.2020.17},
  URN =		{urn:nbn:de:0030-drops-137669},
  doi =		{10.4230/OASIcs.iPMVM.2020.17},
  annote =	{Keywords: Nanotribology, Friction, Scratching, Lubrication, Lennard-Jones Potential}
}
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