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Orthogonal turning simulations for casted steel alloy using mesh free methods
Publikationstyp
Conference Paper
Date Issued
2019-09
Sprache
English
Herausgeber*innen
Other Contributor
TORE-URI
Start Page
337
End Page
346
Citation
Congress of the German Academic Association for Production Technology, WGP: 337-346 (2019)
Publisher DOI
Publisher
Springer Vieweg
Automobile components have to fulfil comprehensive requirements in terms of functional performance, reliability and production cost which are at the leading edge of technology. For that, they often undergo machining operations. Robust, high-precision machining processes are critical to the reduction of scrap rates which severely affect the cost per part. Owing to this reason, computational modelling of machining by means of the Finite Element Method (FEM) has gained increased emphasis in recent years in order to enhance process design and optimization. A major drawback of FEM in modelling of machining, however, is the handling of mesh distortions which are inherent to cutting processes. In contrast, mesh-free methods such as Smooth Particle Hydrodynamics (SPH) or Smooth Particle Galerkin (SPG) methods eliminate this drawback. Hence, this paper focuses on the mesh-free simulation of orthogonal turning of a recent cast steel alloy using the SPH and SPG methods. Simulations of variable particle diameters do indicate low do to be favorable for both methods. Forces and chips from mesh-free simulations were compared against FEM simulation and experimental results. Simulations in LS-DYNA and experiments both using Design of Experiments (DoE) were carried out in order to investigate the effects of cutting velocity, feed and rake angle on force components, which demonstrate good agreement of results from mesh-free simulations and tests. With the mesh-free methods the effort to model the machining process was significantly decreased compared to the FEM, however at the expense of higher computation time. In future, mesh-free methods, especially SPG, can significantly improve the efficiency of the machining process layout reducing today’s mostly experimental expense, which arises in particular for recent materials, thereby contributing to the production at the leading edge of technology.
Subjects
Machining
Turning
Finite Element Method
Simulation
DDC Class
600: Technik
620: Ingenieurwissenschaften
660: Technische Chemie
670: Industrielle Fertigung