TY - JOUR

T1 - Fast, curvature-based prediction of rolling forces for porous media based on a series of detailed simulations

AU - Wiederkehr, Thomas

AU - Klusemann, B.

AU - Svendsen, B.

AU - Müller, Heinrich

PY - 2011/4

Y1 - 2011/4

N2 - Using thermal spraying various surface coatings consisting of different material compositions can be manufactured. Besides different solid phases the resulting coating microstructure often contains a non-negligible amount of pores. In this context a roller burnishing process with a hydrostatic ball-point-tool is examined to compact the thermally sprayed coating, thereby reducing porosity. The rolling process is performed by a robot on free-formed workpieces. A simulation concept for the prediction of forces in a robot-guided roller burnishing process based on a series of detailed ABAQUS simulations is presented. It is shown that, based on these test configurations, the process forces can be calculated much faster and with sufficient precision. Thereby an optimal rolling path, which requires the least amount of normal force to be applied, can be determined efficiently leading to the decision whether a specific robot is equipped to handle the path. Furthermore, the described approach may be used as a pattern to apply similar methods to other engineering problems where accurate simulative solutions exist, but cannot be applied to problems of realistic size due to their expenditure of time.

AB - Using thermal spraying various surface coatings consisting of different material compositions can be manufactured. Besides different solid phases the resulting coating microstructure often contains a non-negligible amount of pores. In this context a roller burnishing process with a hydrostatic ball-point-tool is examined to compact the thermally sprayed coating, thereby reducing porosity. The rolling process is performed by a robot on free-formed workpieces. A simulation concept for the prediction of forces in a robot-guided roller burnishing process based on a series of detailed ABAQUS simulations is presented. It is shown that, based on these test configurations, the process forces can be calculated much faster and with sufficient precision. Thereby an optimal rolling path, which requires the least amount of normal force to be applied, can be determined efficiently leading to the decision whether a specific robot is equipped to handle the path. Furthermore, the described approach may be used as a pattern to apply similar methods to other engineering problems where accurate simulative solutions exist, but cannot be applied to problems of realistic size due to their expenditure of time.

KW - Engineering

UR - http://www.scopus.com/inward/record.url?scp=79953232329&partnerID=8YFLogxK

U2 - 10.1016/j.advengsoft.2011.01.001

DO - 10.1016/j.advengsoft.2011.01.001

M3 - Journal articles

AN - SCOPUS:79953232329

VL - 42

SP - 142

EP - 150

JO - Advances in Engineering Software

JF - Advances in Engineering Software

SN - 0965-9978

IS - 4

ER -