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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 -
Effect of Process Parameters on Melt Pool Geometry in Laser Powder Bed Fusion of Metals: A Numerical Investigation
(2022)Procedia CIRP ~ 21st CIRP Conference on Electro Physical and Chemical Machining, ISEM XXINumerical simulation of melt pool behavior during laser powder bed fusion (LPBF) is essential to provide more effective control of the process and choose an optimal set of input parameters for defect-free fabrication. In this work, we use the smoothed particle hydrodynamics (SPH) method to investigate the impact of laser power and scan speed on the melt pool geometry in LPBF. The developments here follow the state-of-the-art numerical ...Conference Paper -
Feedback stabilization of forming processes
(2021)IFAC-PapersOnLineWe develop online feedback control for forming processes governed by nonlinear material models. A novel approach based on a description using partial differential equation governing time-dependent viscoplastic deformations is proposed. The derivation of the feedback control law is based on a Lyapunov analysis of the linearised partial differential equation. Analytically and in the spatially one-dimensional setting exponential decay of the ...Conference Paper -
Material properties of features produced from EN AW 6016 by wire-arc additive manufacturing
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingWire-arc additive manufacturing is an additive manufacturing technology which allows for high deposition rates and is well suited for manufacturing larger parts in a short time compared to other additive manufacturing technologies. The technology has already received considerable industrial take-up for various materials and applications. The aim of this work is to investigate the alloy EN AW 6016 as wire stock for WAAM. To establish this, ...Conference Paper -
Development of tool paths for multi-axis single stage incremental hole-flanging
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingIn this paper, multi-axis single stage incremental hole-flanging is explored in place of three axis multi-stage tool paths in order to prevent flange conicity in hole-flanging by single point incremental forming (SPIF). The angle of inclination of the forming tool, the starting radius and step size of the tool paths are varied to investigate the feasibility of new tool paths. Using the proposed tool paths, an optimization is performed by ...Conference Paper -
On the potential of using selective laser melting for the fast development of forging alloys at the example of waspaloy
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingForged high-performance components form the basis of technical innovations in the energy and transport sector. Great efforts are undertaken to develop new materials for forging, aiming at optimizing both the material performance and the effort needed for materials processing. The development of new forging alloys is accomplished using computational methods in combination with experimental techniques. The experimental characterization is ...Conference Paper -
On the numerical prediction of process-dependent properties of current high-performance materials with material model *MAT_254 in LS-DYNA
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingOver the last years, the forecast quality in production and especially (cold) forming simulations has reached a high level at least for standard materials. It has become state-of-the-art to take the results of these process simulations into account e.g. for crashworthiness analyses. For most of the currently used high-performance materials, however, the manufacturing processes do not only result in plastic deformation and thinning of the ...Conference Paper -
Mathematical modeling and optimization for powder-based additive manufacturing
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingIn powder-bed additive manufacturing, a laser beam melts a thin layer of metallic powder, which solidifies during cooling and bonds to the already processed solid material. After finishing one layer, the surface is covered with a new thin powder layer, and the melting process iterates, until an entire three-dimensional object emerges. Current scanning strategies are not optimized with respect to certain optimality criteria such as ...Conference Paper -
Prediction of mechanical properties of Ti-6Al-4V forgings based on simulation of microstructure evolution
(2020)Procedia Manufacturing ~ 23rd International Conference on Material FormingTitanium alloys are widely used in the aerospace industry as a structural material. Since this application is critical, the titanium alloys must have high mechanical properties both at room and at elevated temperatures. The thermomechanical processing of titanium alloys during forging determines the microstructure of the manufactured parts to a large extend. The final mechanical properties are attained by the subsequent heat treatment. ...Conference Paper