Computational Mechanics Role in Solving Manufacturing Problems
Troy Marusich (Third Wave Systems)
Symposium in honor of Rod Clifton on the occasion of his 75th Birthday
Mon 10:45 - 12:15
Salomon 101
Manufacturing processes play a critical role in the global industrial base. Machining is one process that is particularly pervasive in the production of components for industries such as automotive, aerospace, defense, medical device, oil and gas, and power generation. Machining is also a process that is rich in physics, encompassing heat transfer, materials, fluids and dynamics. This paper provides details of approaches taken to apply computational mechanics to model the complex multi-physics and multi-scale problem of machining and then apply the model outputs to solving manufacturing problems. First, a detailed description of the physics-based models is provided. An explicit dynamic finite element code is employed, containing deformable body contact, three-dimensional fully adaptive remeshing, finite deformation kinematics and transient heat transfer. Integrated into the model are constitutive models capable of representing the large deformation (true strains >1), high strain rate (>105) and temperatures near melt. The thermal and mechanical loads experienced through the application of coolant are detailed using smooth particle hydrodynamics (SPH) to round out the tightly coupled thermal-fluid-structure interaction problem. Computational improvements are provided for modern multi-core workstation and server environments through the implementation of shared memory parallelization. These improvements are leveraged with a cloud computing simulation capability. Validation of the model is performed through the measurement of cutting forces and chip morphology from simple orthogonal machining tests through complex milling and drilling tests. Finally, some examples of application of the model to solve manufacturing problems from tool fracture, abrasive and diffusive wear, and workpiece residual stress and microstructure modeling are provided.