Physical Modeling for Virtual Manufacturing Systems and Processes

Volume 869

doi: 10.4028/

Paper Title Page

Authors: Zhi Bo Zhang, Herbert M. Urbassek
Abstract: We compare the performance of three interatomic interaction potentials for describing the evolution of plasticity and phase transformations in Si: the well established Stillinger-Weber potential, a recent modification used in the description of Al/Si composites, and a modification of the well known Tersoff potential. We show that the generation of dislocations and the evolution of plasticity are well described by the Stillinger-Weber potential and its modification, while the phase transformation to the high-pressure bct5 modification and the subsequent amorphization are better included in the modified Tersoff potential.
Authors: Jonas Lukasczyk, Garrett Aldrich, Michael Steptoe, Guillaume Favelier, Charles Gueunet, Julien Tierny, Ross Maciejewski, Bernd Hamann, Heike Leitte
Abstract: We present a methodology to analyze and visualize an ensemble of finite pointset method (FPM) simulations that model the viscous fingering process of salt solutions inside water. In course of the simulations the solutions form structures with increased salt concentration value, called viscous fingers. These structures are of primary interest to domain scientists since it is not deterministic when and where viscous fingers appear and how they evolve. To explore the aleatoric uncertainty embedded in the simulations we analyze an ensemble of simulation runs which differ due to stochastic effects. To detect and track the viscous fingers we derive a voxel volume for each simulation where fingers are identified as subvolumes that satisfy geometrical and topological constraints. Properties and the evolution of fingers are illustrated through tracking graphs that visualize when fingers form, dissolve, merge, and split. We provide multiple linked views to compare, browse, and analyze the ensemble in real-time.
Authors: Anthony Beaucamp
Abstract: Materials such as binderless tungsten carbide and silicon carbide have become ubiquitous in the fabrication of high-performance tooling and molding inserts. But while conventional grinding of these hard ceramics has been studied in depth, the theory underlying their super-fine finishing has been less extensively explored. In particular, the boundary in process parameters that delineates the brittle/ductile removal transition remains mostly undocumented. In this paper, we review some super-fine finishing methods for carbide materials, based on both bound and kinetic abrasive processes. The focus is then placed on modelling the interaction between material and abrasives under their respective process conditions, and deriving some useful criteria guiding the brittle/ductile transition.
Authors: Alexander Schlüter, Charlotte Kuhn, Timo Noll, Felix Diewald, Ralf Müller
Abstract: This work discusses the efficiency of six strategies for the numerical solution of the coupled system of partial differential equations that arise from a phase field description of dynamic fracture. Efficient numerical treatment of the dynamic phase field fracture model is a prerequisite for the simulation of failure due to brittle fracture in realistic scenarios such as manufacturing.Firstly, the phase field description of fracturing of brittle solids is introduced. Afterwards, three monolithic as well as three staggered finite element solution strategies are outlined and their performance is studied in two benchmark problems.
Authors: Matthias Sabel, Christian Sator, Ralf Müller, Benjamin Kirsch
Abstract: The formation of chips in cutting processes is characterised by large deformations and large configurational changes and therefore challenges established modeling techniques. To overcome these difficulties, the particle finite element method (PFEM) combines the benefits of discrete modeling techniques with methods based on continuum mechanics. In this work an outline of the PFEM, as well as an explanation of the finite element formulation are provided. The impact of the boundary detection on the structural integrity is studied. The numerical examples include a tensile test as well as cutting simulations. The paper is concluded by a comparison of cutting forces with analytical results.
Authors: Dinesh Setti, Benjamin Kirsch, Jan Christian Aurich
Abstract: Visualization of work surface topography through simulations is very challenging task in grinding process due to the complexity of wheel-work interactions with a very high number of cutting points (grits). Kinematic mapping of abrasive grits on a three-dimensional wheel topography enables the evaluation of ground surface topography through simulations. In this paper, a method for generating the ground surface topography based on wheel specifications is presented. Abrasive grits size, abrasives volume percentage and their nature of distribution on the wheel surface are considered in the modeling and visualization of wheel topography. The simulation results of ground surface topographies prove the feasibility of the developed method.
Authors: Arash Gobal, Bahram Ravani
Abstract: Selective Laser Sintering (SLS) has recently become one of the fastest growing additive manufacturing processes due to its capability of fabricating metal parts with high dimensional accuracy and surface quality. Physical modeling of this process plays an important role in properly controlling the process parameters of the process. In this paper, we present a 3 dimensional, adaptive discrete element method for simulation of the SLS process on personal computers. The presented method models the laser-powder interaction at particle level, achieving high simulation accuracy while adaptively increasing the discrete element size as local temperatures drop inside the powder bed for improved efficiency. Numerical shape functions are developed for calculating individual particle temperatures at any point during the simulation. Results show that this physical model improves the runtime significantly in virtual simulation of SLS process without loss of simulation accuracy.
Authors: Martin P. Lautenschlaeger, Simon Stephan, Herbert M. Urbassek, Benjamin Kirsch, Jan Christian Aurich, Martin Thomas Horsch, Hans Hasse
Abstract: Physical phenomena in a nanometric machining process were studied by molecular dynamics simulations. A cylindrical tool was indented and then moved laterally on an initially flat workpiece. The focus of the study is on the effect of lubrication on the nanoscale. Therefore, the indentation and the scratching were studied both in vacuum and submersed in a lubricant. All materials were modeled by Lennard-Jones truncated and shifted potential sites. It is observed, that in the lubricated case, a substantial part of the cutting edge of the tool is in dry contact with the workpiece. Nevertheless, compared to the dry scenario, the lubrication lowers the coefficient of friction. However, the work which is needed for the indentation and the scratching is not reduced. The processed surface is found to be smoother in the lubricated case. As expected, the lubrication has an important influence on the temperature field observed in the simulation.
Authors: José L. York Duran, Charlotte Kuhn, Ralf Müller
Abstract: On the macrolevel metal matrix composites (MMCs) resemble a homogeneous material. However, on the microlevel they have an inhomogeneous microstructure. This paper will show how heterogeneities affect the effective macroscopic properties the material, i.e. the effective properties. This investigation is done using computational homogenization techniques. Finite element (FE) simulations were conducted in ABAQUS in combination with MATLAB, using material parameters for aluminum alloy AA2124 and silicon carbide SiC to develop a representative volume element (RVE) of the MMC AMC217xe.

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