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Wire-EDM geometrical simulation based on superposition of single craters
(2023)Procedia CIRP ~ 19th CIRP Conference on Modeling of Machining OperationsSetting EDM technology parameters is a time consuming and expensive process. The development of a process model facilitates the understanding of the input parameters on the process results, which can speed up the selection of the optimal technology for a cut. This work aims to model the wire-EDM machining process with a three-dimensional geometrical voxel model through the sequential placement of single craters. To model workpiece sizes ...Conference Paper -
Geometric-kinematic model for wear simulation of diamond-impregnated segments in concrete core drilling
(2023)Procedia CIRP ~ 19th CIRP Conference on Modeling of Machining OperationsThe main concerns during the development of new diamond-impregnated segments in concrete core drilling are the tool lifetime and its capacity to self-sharpen, since tool sharpening is, most of the time, not acceptable under the conditions on the construction site. However, development only based on experiments can be very costly, considering that the amount of material and workforce are quite demanding. One of the solutions to overcome ...Conference Paper -
iMFREE: A versatile software tool for modelling machining processes with particle methods
(2023)Procedia CIRP ~ 19th CIRP Conference on Modeling of Machining OperationsThe current state-of-the-art for the simulation of machining process is the application of the FEM (finite element method). Nevertheless, the cost of FEM analyses for such problems is high due to their complex multi-physics nature, mesh regeneration issues, and small time-length scales. In contrast, particle methods are an alternative numerical approach well-suited for large deformations as in material's chip formation. In this work, the ...Conference Paper -
Study on the effect of wear models in tool wear simulation using hybrid SPH-FEM method
(2023)Procedia CIRP ~ 19th CIRP Conference on Modeling of Machining OperationsThe prediction of the tool wear progression using numerical methods has been widely studied in recent years, and various wear models considering different wear mechanisms have been implemented in the simulation work. Typically, these wear models take the physical fields such as contact pressure, sliding velocity and temperature at the tool-workpiece interface into account and are applied either individually or in combinations into the ...Conference Paper -
CA single track simulation of laser conduction welding with stainless steel 316L (1.4404)
(2022)Procedia CIRPThe study presents a coupled cellular automata (CA) approach for a single track microstructure simulation used for laser conduction welding. A high-power CO2 laser beam (1000W) traverses the substrate, with the beam shaped by conventional optics, which produces a Gaussian profile. The process relies on a shallow melt phase to maintain a conduction limited weld. Laser conduction welding does not require a filler material. The stainless ...Conference Paper -
An action-oriented teaching approach for intelligent and energy efficient precision manufacturing
(2022)Manufacturing Letters ~ 50th SME North American Manufacturing Research Conference (NAMRC 50,2022)Thermal errors of machine tools are a major contributor to inaccuracies of produced workpieces. Especially, the reduction of thermal errors without increasing the energy consumption of the machine tool and the shop floor due to exact air conditioning has a great social, scientific, and industrial relevance. Therefore, the Institute of Machine Tools and Manufacturing (IWF) at ETH Zürich set up a series of three lab courses to increase the ...Conference Paper -
Effect of particle size distribution width on repeatability of coating characteristics in atmospheric plasma spraying
(2022)Procedia CIRP ~ 21st CIRP Conference on Electro Physical and Chemical Machining, ISEM XXIAtmospheric plasma spraying (APS) is a widely used thermal spraying process for producing coatings for various applications. The characteristics of the produced coatings is influenced by multiple tens of process parameters and their complex interactions. Even when the same process parameters are used, there is a considerable variability in the characteristics of the produced coatings. The poor repeatability of the coating characteristics ...Conference Paper -
Transfer learning of neural network based process models in Direct Metal Deposition
(2022)Procedia CIRP ~ Leading manufacturing systems transformation – Proceedings of the 55th CIRP Conference on Manufacturing Systems 2022Direct Metal Deposition is an effective additive manufacturing technology to build parts from scratch, add complex features on existing raw parts or even repair highly specialized products. The combinations of high performance materials and free shape complexity achievable by such technology offers great advantages for industrial applications such as the aeronautic industry, where lightweight parts are crucial. However, the complexity of ...Conference Paper -
Height prediction in Directed Metal Deposition with Artificial Neural Networks
(2022)Procedia CIRP ~ 21st CIRP Conference on Electro Physical and Chemical Machining, ISEM XXIDirected Metal Deposition (DMD) is a promising metal additive manufacturing technology, where parts are manufactured by fusing injected metal powder particles with a laser beam moving along a predefined trajectory. A toolpath typically includes sections as curves or edges, where machine axes need to decelerate and accelerate accordingly. As a result, the locally applied laser energy and powder density vary during the deposition process, ...Conference Paper -
Picosecond pulsed laser machining of hardened martensitic stainless steel drive shaft
(2022)Procedia CIRP ~ 21st CIRP Conference on Electro Physical and Chemical Machining, ISEM XXIA fundamental method for estimating the laser parameters and for predicting the achievable ablation rate is demonstrated for hardened martensitic stainless steel X46Cr13. The laser ablation rate is evaluated for a range of pulse energies. The effective threshold fluence for ablation and the effective penetration depth are determined for a low and a high energy regime applying the Neuenschwander model. These parameters are used for numerical ...Conference Paper