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Documents authored by Prieto, Juan Manuel Rodríguez

Document
DOI: 10.4230/OASIcs.iPMVM.2020.13
An Improved Particle Finite Element Method for the Simulation of Machining Processes

Authors: Xialong Ye, Juan Manuel Rodríguez Prieto, and Ralf Müller

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 is one of the most common and versatile manufacturing processes in industry, e.g. automotive industry and aerospace industry. But classical numerical methods such as the Finite Element Method (FEM) have difficulties to simulate it, because the material undergoes large deformations, large strain, large strain rates and high temperatures in this process. One option to simulate such kind of problems is the Particle Finite Element Method (PFEM) which combines the advantages of continuum mechanics and discrete modeling techniques. In this study we develop the PFEM further and call it the Adaptive Particle Finite Element Method (A-PFEM). Compared to the PFEM the A-PFEM enables insertion of particles and improves significantly the mesh quality along the numerical simulation. The A-PFEM improves accuracy and precision, while it decreases computing time and resolves the phenomena that take place in machining. Because metal cutting involves plastic deformation we resort to the J₂ flow theory with isotropic hardening. At last some numerical examples are presented to compare the performance of the PFEM and A-PFEM.
Cite as

Xialong Ye, Juan Manuel Rodríguez Prieto, and Ralf Müller. An Improved Particle Finite Element Method for the Simulation of Machining 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. 13:1-13:9, Schloss Dagstuhl – Leibniz-Zentrum für Informatik (2021)

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@InProceedings{ye_et_al:OASIcs.iPMVM.2020.13,
  author =	{Ye, Xialong and Prieto, Juan Manuel Rodr{\'\i}guez and M\"{u}ller, Ralf},
  title =	{{An Improved Particle Finite Element Method for the Simulation of Machining Processes}},
  booktitle =	{2nd International Conference of the DFG International Research Training Group 2057 – Physical Modeling for Virtual Manufacturing (iPMVM 2020)},
  pages =	{13:1--13:9},
  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.2020.13},
  URN =		{urn:nbn:de:0030-drops-137628},
  doi =		{10.4230/OASIcs.iPMVM.2020.13},
  annote =	{Keywords: Particle Finite Element Method, Alpha Shape Method, Metal Cutting}
}
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.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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