Methods for efficient and accurate calculation of the static receptance and eigenpairs of a thin-walled workpiece

• Applicant: Professor Dr.-Ing. Christian Brecher
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2023
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 518689593

Due to the varying static and dynamic properties during the machining process, the CAM planning of a thin-walled workpiece is a costly and time-consuming task. Traditionally, many machining tests are required to iteratively optimize the process parameters. The static and dynamic properties of the thin-walled workpiece can be predicted with existing simulation methods. These predicted properties can be used during the CAM planning to reduce the number of the required machining tests to optimize the process parameters. Thereby the associated material and time costs are saved. The physical properties of the thin-walled workpiece are not constant due to material removal during the machining process. Therefore, many simulations of intermediate are necessary to accurately determine the variation of the physical properties. The involved large computational cost has greatly limited the usage of existing simulation methods. The focus of this research project is henceforth to develop a framework that addresses the following research questions:1. How can the intermediate states of the thin-walled workpiece be systematically and scientifically selected to reduce the overall computational cost and guarantee the accuracy of the prediction? 2. How can the FE systems of the intermediate states of the thin-walled workpiece be created efficiently and automatically? 3. How can the FE systems of the intermediate states of the thin-walled workpiece be efficiently and accurately solved to predict the varying static and dynamic properties of the workpiece? The first step is to develop an interface between the virtual machining and the FE simulation of the thin-walled workpiece. Based on this interface, different methods for the efficient and accurate FE simulation workpiece are explored. All developed methods are integrated into a software framework as separate software modules. Extensive machining tests and measurements are performed to evaluate the developed methods and the software framework. It is expected that the efficiency and accuracy of the FE simulation of a thin-walled workpiece can be significantly improved by the methods developed within this project.

• DFG Programme: Research Grants
• Co-Investigator: Dr.-Ing. Marcel Fey