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Efficient optimization of turning processes for powertrain components using multi model-based simulation
Citation Link: https://doi.org/10.15480/882.16917
Publikationstyp
Doctoral Thesis
Date Issued
2026
Sprache
English
Author(s)
Advisor
Referee
Title Granting Institution
Technische Universität Hamburg
Place of Title Granting Institution
Hamburg
Examination Date
2025-10-16
Institute
TORE-DOI
First published in
Number in series
58
Citation
Wissen schafft Innovation 58: (2026)
In this thesis, various simulation methods for the analysis and optimization of turning processes in mass-scale production are developed and presented. The dry turning process was optimized by conducting simulations of different coating tools, coating thicknesses and tool cutting edge radii in commercial FEM software AdvantEdge. All simulations were experimentally validated. Two new simulation approaches were developed for flood lubricated turning process which significantly expanded the application of simulations. In the first approach, a coupling between two different software tools was developed and implemented. This solution coupled a commercial FEM tool (AdvantEdge) with a commercial CFD tool (Star-CCM+). In the second approach, a single software, LS-DYNA, was used to simulate flood lubricated orthogonal turning simulations. These simulations were additionally validated with literature and were compared to dry orthogonal turning simulations. Lastly, mechanistic modelling method was used in the MACHpro software to optimize the NC-program of inner contour turning process in mass production of turbine housing. For this purpose, a digital force model using FEM simulations was developed in order to optimize the NC program by means of feed-rate adjustments. By implementing these simulation results in mass-production, the tool life could be increased by 46%. Additionally, the best performing coating and coating thickness from the dry machining simulation was simulated with the mass production cutting insert geometry. In production tests, the optimized coating achieved a further increase of almost 75% in tool life and a reduction of 64% in the scrap costs.
Subjects
Simulation
Machining
Finite element method
Computational fluid dynamics
Mass production
DDC Class
620: Engineering
Publication version
acceptedVersion
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Rana_Pulkit_2026_Efficient_optimization_of_turning_processes_for_powertrain_components_using_multi_model-based_simulation.pdf
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