Manufacturing Engineering

Process virtualization in manufacturing engineering provides valuable tools for engineers as they gain important insights into their processes long before the first tool is actually built.

It is a challenging task to model the processes appropriately. Classical mesh-based methods, such as Finite Element Methods (FEM), are very suitable to simulate structural mechanical properties of the workpiece; but they require high efforts for 3D meshing and coupling – if it is even possible – to model dynamical manufacturing processes. This is relevant, for example, when large deformations or cooling fluids are involved.

Advantages of MESHFREE:

  • The moving point cloud approach is naturally suited to the dynamical simulation of manufacturing processes. Large changes in topology are manageable without the need for remeshing as in FEM methods.
  • For a 3D simulation, MESHFREE only requires 2D surface meshes of the geometry. These are already available within widely used CAD tools at no extra effort.
  • The scripting language enables easy incorporation of user-defined damage models.

MESHFREE Use Cases – Metal Cutting

Within DFG projects in cooperation with the Chair of Machine Tools and Factory Management (IWF, TU Berlin), we have developed simulation models for dry and wet metal cutting.

Influence of cutting fluid on temperature distribution and chip shape for a cylindric turning process.

Heat is generated due to friction and plastic deformation causing thermal damage of the tools and thermal distortion of the workpiece that can be avoided by utilizing cutting fluids.