Title: Orthogonal turning simulations for casted steel alloy using mesh free methods
Language: English
Authors: Rana, Pulkit 
Hintze, Wolfgang 
Zielasko, Waldemar 
Schuster, Thomas 
Editor: Wulfsberg, Jens Peter 
Hintze, Wolfgang 
Behrens, B.-A. 
Keywords: Machining;Turning;Finite Element Method;Simulation
Issue Date: 2019
Publisher: Springer Vieweg
Source: Production at the leading edge of technology : Proceedings of the 9th Congress of the German Academic Association for Production Technology (WGP), September 30th - October 2nd, Hamburg 2019 / ed. by J. P. Wulfsberg, W. Hintze, B.-A. Behrens. - Berlin : Springer Vieweg, 2019. - Seite 337-346
Abstract (english): 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.
Conference: 9th Congress of the German Academic Association for Production Technology (WGP), Hamburg, September 30 - October 2, 2019 
URI: http://hdl.handle.net/11420/5515
ISBN: 978-3-662-60417-5
Institute: Produktionsmanagement und -technik M-18 
Type: InProceedings (Aufsatz / Paper einer Konferenz etc.)
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