M.Sc.

Ganser, Philipp

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  • Publication
    Knowledge-Based Adaptation of Product and Process Design in Blisk Manufacturing
    ( 2022)
    Ganser, Philipp
    ;
    Landwehr, Markus
    ;
    Schiller, Sven
    ;
    Vahl, Christopher
    ;
    Mayer, Sebastian
    ;
    Bergs, Thomas
    Early and efficient harmonization between product design and manufacturing represents one of the most challenging tasks in engineering. Concepts such as simultaneous engineering aim for a product creation process, which addresses both, functional requirements as well as requirements from production. However, existing concepts mostly focus on organizational tasks and heavily rely on the human factor for the exchange of complex information across different domains, organizations, or systems. Nowadays product and process design make use of advanced software tools such as computer-aided design, manufacturing, and engineering systems (CAD/CAM/CAE). Modern systems already provide seamless integration of both worlds in a single digital environment to ensure a continuous workflow. Yet, for the holistic harmonization between product and process design, the following aspects are missing: (i) the digital environment does not provide a complete and data consistent digital twin of the component; this applies especially to the process design and analysis environment, (ii) due to the lack of process and part condition data in the manufacturing environment, an adaptation of product and process design for a balanced functionality and manufacturability is hindered, and (iii) systematic long-term data analytics across different product and process designs with the ultimate goal to transfer knowledge from one product to the next and to accelerate the entire product development process is not considered. This paper presents an exploration concept which couples product design (CAD), process design (CAM), process simulation (CAE), and process adaptation in a single software system. The approach provides insights into correlations and dependencies between input parameters of product/process design and the process output. The insights potentially allow for a knowledge-based adaptation, tackling well-known optimization issues such as parameter choice or operation sequencing. First results are demonstrated using the example of a blade integrated disk (blisk). Early and efficient harmonization between product design and manufacturing represents one of the most challenging tasks in engineering. Concepts such as simultaneous engineering aim for a product creation process, which addresses both, functional requirements as well as requirements from production. However, existing concepts mostly focus on organizational tasks and heavily rely on the human factor for the exchange of complex information across different domains, organizations, or systems. Nowadays product and process design make use of advanced software tools such as computer-aided design, manufacturing, and engineering systems (CAD/CAM/CAE). Modern systems already provide seamless integration of both worlds in a single digital environment to ensure a continuous workflow. Yet, for the holistic harmonization between product and process design, the following aspects are missing: (i) the digital environment does not provide a complete and data consistent digital twin of the component; this applies especially to the process design and analysis environment, (ii) due to the lack of process and part condition data in the manufacturing environment, an adaptation of product and process design for a balanced functionality and manufacturability is hindered, and (iii) systematic long-term data analytics across different product and process designs with the ultimate goal to transfer knowledge from one product to the next and to accelerate the entire product development process is not considered. This paper presents an exploration concept which couples product design (CAD), process design (CAM), process simulation (CAE), and process adaptation in a single software system. The approach provides insights into correlations and dependencies between input parameters of product/process design and the process output. The insights potentially allow for a knowledge-based adaptation, tackling well-known optimization issues such as parameter choice or operation sequencing. First results are demonstrated using the example of a blade integrated disk (blisk).
  • Publication
    Influence of heat treatment on the residual stress-related machining distortion of Ti-6Al-4V alloy monolithic parts
    ( 2021)
    Landwehr, Markus
    ;
    Oehler, Farina
    ;
    Behnken, Herfried
    ;
    Holling, Hendrik
    ;
    Sambathkumar, Raveeshankar
    ;
    Ganser, Philipp
    ;
    Bergs, Thomas
    Machining distortion caused by residual stresses is one of the major challenges in the production of thin-walled monolithic parts. One reason for the distortion is the relaxation of the initial residual stresses within the raw part due to the material removal during the machining process. The initial residual stresses mainly depend on the manufacturing process of the raw part and the subsequent heat treatment. This paper presents the results from a set of experimental and computational studies of the influence of heat treatment on residual stress-related machining distortion of Ti-6Al-4V alloy monolithic parts. A thermo-mechanical simulation of the heat treatment process is developed for the prediction of the initial residual stresses. For experimental validation, the contour method is use d to quantify the initial residual stresses. Finally, machining tests are conducted to measure the final part distortion for two different residual stress states.
  • Publication
    The finite cell method for the prediction of machining distortion caused by initial residual stresses in milling
    ( 2021)
    Landwehr, Markus
    ;
    Schmid, Sebastian
    ;
    Holla, Vijaya
    ;
    Ganser, Philipp
    ;
    Bergs, Thomas
    ;
    Ruess, Martin
    ;
    Schröder, Kai-Uwe
    Machining distortion caused by residual stresses is one of the major challenges in the production of thin-walled monolithic parts, which are widely used in the aerospace industry. This distortion often results in large deviations in form and position outside the tolerance requirements of the part. Time-consuming and cost-intensive running-in processes or manual reworking are therefore necessary to meet the tolerances of the parts. Current research mainly uses the finite element method (FEM) to predict machining distortion caused by residual stresses. However, the disadvantage of the FEM is the high manual effort required to generate a computational mesh of the in-process workpiece (IPW). Moreover, the FEM demands a very fine mesh, which has to be frequently updated by remeshing, to be in good agreement with the IPW. This leads to high computation times overall. In this paper, a novel machining distortion prediction method based on the Finite Cell Method (FCM) is presented. A major advantage of FCM compared to the established FEM in the context of milling simulation is the decoupling of the computational mesh and the IPW geometry, which allows for analysis updates of the modified IPW due to material removal, without the need for expensive re-meshing. Thus, the time complexity of the simulation can be reduced significantly. The milling process of a thin-walled part made of Ti-6Al-4V was considered to demonstrate the overall simulation approach.