1006 Multiphysics Modeling of Subtractive and Additive Manufacturing Processes with Advanced Meshfree Methods

  • Mohamadreza Afrasiabi, ETH Zurich
  • Mehrshad Mehrpouya, University of Twente
  • Hagen Klippel, ETH Zurich
  • Fatih Bosna, ETH Zurich

1000 - Manufacturing and Materials Processing

Keywords: manufacturing processes; multiphysics modeling; numerical simulation; meshfree methods; parallel computing.

Organizer: Dr. Mohamadreza Afrasiabi (ETH Zurich)
Co-organizers: Prof. Dr. Mehrshad Mehrpouya (University of Twente), Mr. Hagen Klippel and Mr. Fatih Bosna (ETH Zurich).


The impact of manufacturing technologies on the economic cycle is enormous and hard to overstate. It is proclaimed that > 10% of the Gross National Product (GNP) only in the US and > 15% of the total added production value in all developed countries are allocated to the cost of manufacturing removal operations [1]. For better productivity in this vast yet ever-growing industry, an in-depth understanding of the underlying physics is crucial to minimize the costs and optimize the process. Doing so, however, is a daunting task as it typically involves several complex phenomena at different time and length scales. Numerical modeling of manufacturing processes is an invaluable tool to establish this understanding, which forms an active area of research and development.

Modeling and simulation of manufacturing processes is inherently a multiphysics problem. Depending on the process, the analysis encounters a broad array of physical phenomena such as optics, heat transfer, mechanical deformation, surface tension, and material phase change, to name a few. The majority of published works in the literature use either mesh-based or particle-based techniques for spatial discretization. Despite their competence and maturity in modeling a wide range of manufacturing processes, mesh-based methods (e.g., FEM) face severe difficulties in handling large deformations, free-surface movements, and complex material-phase interfaces. On the other hand, particle-based methods are naturally capable of addressing these issues because of their mesh-free Lagrangian characteristics.

Another promising feature of particle methods is their suitability for parallelization, especially for GPU-based implementations. Due to the high computational cost of manufacturing simulations in most cases, it appears that the scale of modeling needs must be leveraged through parallel and high-performance computing to fully realize the benefits of a process modeling and simulation capability. This is, in fact, a vital consideration allowing us to perform a series of parameter studies, sensitivity analyses, and high particle resolutions, which are often demanded by manufacturing industries.

This mini-symposium (MS) will provide a multi-disciplinary forum on particle-based computational models of manufacturing and materials processing technologies. We welcome contributions on all areas of subtractive and additive processes. Examples include:

- Subtractive processes: orthogonal cutting, grinding, drilling, etc.
- Additive processes: powder bed fusion (PBF), selective laser sintering (SLS), direct metal deposition (DMD), material extrusion, etc.

The submissions to this MS are expected to focus on meshfree simulations using commercial, open-source, or in-house codes with a novel development to the current state of the art. Any of the various meshfree schemes such as Smoothed Particle Hydrodynamics (SPH), Reproducing Kernel Particle Method (RKPM), Particle Strength Exchange (PSE), Finite Point Method (FPM), Material Point Method (MPM), and Optimal Transportation Meshfree (OTM) may be chosen for modeling the manufacturing problem of interest. The contributions performed on parallel architectures (CPUs and GPUs) by utilizing high-performance computing (HPC) algorithms are particularly appreciated. It is strongly discouraged to present simulation results without any experimental validation.

The research focus may be methodological or phenomenological; nonetheless, contribution to this MS should adopt a multiphysics modeling approach, which incorporates novel mathematical/computational frameworks using meshfree particle-based methods. The proposed new developments and strategies should offer improvements in the accuracy and/or efficiency of meshfree methods for the numerical simulation of manufacturing processes.
[1] Milton Clayton Shaw. Metal cutting principles. Vol. 2. Oxford university press New York, 2005

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