Explanipedia

NUMERICAL INVESTIGATION OF TOOL WEAR EFFECTS ON PROCESS QUANTITIES DURING TURNING OF AISI 4140 Open

Armel Zambou Kenfack, Jens Sölter, Bernhard Karpuschewski · 2025

To manufacture components with a certain pre-defined surface integrity, it is important to understand how tool wear affects the machined workpiece. In this work, an approach is proposed to simulate the effect of tool wear based on measured…

A phenomenological constitutive model for deep rolling process simulation of AISI 4140 under high dynamic conditions Open

Z. Y. Chen, Matthias Hettig, Jan Schubnell, Jens Sölter, Daniel Meyer · 2025

Well-informed neural network: an approach for the prediction of the width of flank wear land in turning processes Open

Susanne Stemmer, B. Papenberg, L. Langenhorst, Jens Sölter, Daniel Meyer , et al. · 2025

Numerical study of parameters affecting surface integrity in machine hammer peening of AISI 4140 Open

Kai Chen, Matthias Hettig, Jens Sölter, Daniel Meyer · 2025

Simulation of chip formation for varying uncut chip thickness during vibration-assisted drilling with the CEL method Open

Lukas Schumski, François Ducobu, L. Langenhorst, Jens Sölter, Bernhard Karpuschewski · 2025

Minimum Quantity Lubrication (MQL) Supply through Internal Cooling Channels in Drilling Processes Open

Lukas Schumski, Teresa Tonn, Jens Sölter, Kerstin Avila, Lizoel Buss , et al. · 2024

Minimum quantity lubrication (MQL) technologies possess great potential for improving the sustainability of manufacturing processes, which can reduce the absolute quantity of metalworking fluid (MWF) and also enable near-dry chips that are…

Finite element simulation of the mechanical loads during low frequency vibration-assisted drilling utilizing the CEL-method Open

Lukas Schumski, Teresa Tonn, Lizoel Buss, Jens Sölter, Udo Fritsching , et al. · 2024

Simultaneous high-speed cutting and high-feed milling: An investigation on surface integrity Open

Gerrit Kuhlmann, Dmytro Borysenko, Jens Sölter, Bernhard Karpuschewski · 2024

Utilizing orthogonal cutting models to predict the fraction of shear plane heat into the workpiece for milling and turning Open

L. Langenhorst, Jens Sölter · 2024

Flow Visualisation and Evaluation Studies on Metalworking Fluid Applications in Manufacturing Processes—Methods and Results Open

Udo Fritsching, Lizoel Buss, Teresa Tonn, Lukas Schumski, Jurgen Gakovi , et al. · 2023

Metalworking operations rely on the successful application of metalworking fluids (MWFs) for effective and efficient operation. Processes such as grinding or drilling often require the use of MWFs for cooling, lubrication, and chip removal…

Minimum Quantity Lubrication (MQL) multiphase dynamics of a vibration-assisted drilling process Open

Lizoel Buss, Lukas Schumski, Jens Sölter, Kerstin Avila, Bernhard Karpuschewski , et al. · 2023

Metalworking fluid (MWF) consumption in machining processes can be minimised using minimum quantity lubrication (MQL). In the vibration-assisted drilling process, the MWF is transported as aerosol (dispersed droplets in gas) to the cutting…

Influence of initial stress on the residual stress generated by deep rolling Open

Tobias Kinner-Becker, Jens Sölter · 2023

Deep rolling is a finishing process and as such, usually used at the end of a process chain. The preceding processes often already have a substantial effect on the surface integrity. However, regarding residual stress, it is normally assum…

Magnetic-abrasive machining in manufacturing of medical implants Open

Bernhard Karpuschewski, Yurii Kotsun, V. S. Maiboroda, Dmytro Borysenko, Maria Herbster , et al. · 2022

Despite the rapid development of new biocompatible medical materials, the question of an optimal mechanical processing of implants surfaces remains a major challenge. Surface integrity of sliding pair surfaces in implant joints is the key …

Process Signatures–Knowledge-based approach towards function-oriented manufacturing Open

Bernhard Karpuschewski, Tobias Kinner-Becker, A. Klink, L. Langenhorst, Joachim Mayer , et al. · 2022

Surface layer properties are of crucial importance for the functional performance of manufactured components. For the vision of a function-oriented production, the relevant surface layer properties for the considered functional properties …

Modification of the Johnson–Cook Material Model for Improved Simulation of Hard Milling High-Performance Steel Components Open

Andrey Vovk, Amin Pourkaveh Dehkordi, Rainer Glüge, Bernhard Karpuschewski, Jens Sölter · 2021

Understanding the effect of thermomechanical loads during finish cutting processes, in our case hard milling, on the surface integrity of the workpiece is crucial for the creation of defined quality characteristics of high-performance comp…

Modelling and Simulation of Mechanical Loads and Residual Stresses in Deep Rolling at Elevated Temperature Open

Sven Kuschel, Tobias Kinner-Becker, Robert Zmich, Jens Sölter, Daniel Meyer · 2021

Based on the concept of Process Signatures, the deep rolling process is analyzed, aiming at functional relationships between material modifications and internal material loads during the process. The focus of this work is to investigate th…

Comparison of Process Signatures for thermally dominated processes Open

Bernhard Karpuschewski, Th. Lübben, Matthias Meinke, Sandro Eckert, F. Frerichs , et al. · 2021

Four machining processes are analyzed with respect to the internal material loads and modifications in the surface layer. The processes considered are grind hardening, induction hardening, laser hardening as well as Electrical Discharge Ma…

Finite element simulation of low frequency vibration-assisted drilling with modification of oscillation modes Open

Lukas Schumski, Tebbe Paulsen, Jens Sölter, Bernhard Karpuschewski · 2021

Low frequency vibration assisted drilling (LFVAD) is an important cutting process, especially for hard-to-machine materials and materials that tend to produce long chips. In LFVAD the continuous axial tool movement in feed direction is sup…

Numerical investigation of the influence of multiple loads on material modifications during hard milling Open

Andrey Vovk, Jens Sölter, Bernhard Karpuschewski · 2021

Understanding the effect of finishing processes on the surface integrity of the workpiece is crucial for the creation of defined functional characteristics in workpieces. The measurement-based determination of the material loads requires a…

Combined laser and deep rolling process as a means to study thermo-mechanical processes Open

Tobias Kinner-Becker, Robert Zmich, Jens Sölter, Daniel Meyer · 2021

In thermo-mechanical processes, the effect of mechanical and thermal loads on resulting material modifications are not independent of each other. In order to analyze and understand their interaction, they should be varied independently fro…

Partition of Primary Shear Plane Heat in Orthogonal Metal Cutting Open

L. Langenhorst, Jens Sölter, Sven Kuschel · 2020

When assessing the effect of metal cutting processes on the resulting surface layer, the heat generated in the chip formation zone that is transferred into the workpiece is of major concern. Models have been developed to estimate temperatu…

Finite element simulations of the material loads and residual stresses in milling utilizing the CEL method Open

Andrey Vovk, Jens Sölter, Bernhard Karpuschewski · 2020

Within the process chain for the production of highly stressed components, finishing is of particular importance - the resulting surface layer properties of the workpiece decisively determine the component functionality. According to the c…

A simulation-based analysis of internal material loads and material modifications in multi-step deep rolling Open

Tobias Kinner-Becker, Jens Sölter, Bernhard Karpuschewski · 2020

The concept of Process Signatures states that material modifications are solely dependent on the acting internal loads during processing, irrespective of the specific process chosen. Knowledge of these correlations would allow the predicti…

A Comparative Study of the Influence of the Strain-Hardening in Chip Formation Simulations using Different Software Packages Open

Nicole Wielki, Sven Kuschel, Jens Sölter · 2019

Childs has proposed a method for the parameterization of the strain-hardening model in orthogonal cutting simulations of carbon steels utilizing the finite element-based software AdvantEdge [1]. The approach led to promising results regard…

A Three Dimensional Calculation Approach for the Heat Flux Density Distribution in Face Milling Open

L. Langenhorst, Mertcan Cihan, Jens Sölter · 2019

In metal cutting, the prediction of thermally induced material alterations, e.g. crack formation, generation of residual tensile stresses, and form deviations of components is of high relevance. This requires the knowledge of the dissipate…

Underlying Mechanisms for Developing Process Signatures in Manufacturing Open

E. Brinksmeier, Stefanie Reese, A. Klink, L. Langenhorst, Th. Lübben , et al. · 2018

The concept of Process Signatures allows the reliable and knowledge-based prediction of material modifications (e.g., changes of hardness, residual stress, microstructure and chemical composition) researchers in the field of surface integr…

Process Signatures - The Missing Link to Predict Surface Integrity in Machining Open

E. Brinksmeier, Daniel Meyer, Carsten Heinzel, Th. Lübben, Jens Sölter , et al. · 2018

The concept of Process Signatures is based on the correlation between the internal material loads in manufacturing processes and the resulting material modifications, thus allowing a deeper and more comprehensive understanding of the under…

Effects of Model Reduction on Simulated Temperature Fields in Milling Open

L. Langenhorst, Maxim Gulpak, Jens Sölter, Oltmann Riemer · 2017

Temperature fields generated in machining processes affect, among other internal material loads, the material modifications in the workpiece surface layer and therefore influence the functional performance of the final component. In partic…

Experimental and Numerical Analysis of Residual Stress Change Caused by Thermal Loads During Grinding Open

Sven Kuschel, B. Kolkwitz, Jens Sölter, E. Brinksmeier, Carsten Heinzel · 2016

A realistic modelling and simulation of the resulting surface integrity e.g residual stresses caused by grinding is limited due to the lack of knowledge to estimate the amount of thermal load affecting the workpiece. This paper deals with …

A Simulation Based Development of Process Signatures for Manufacturing Processes with Thermal Loads Open

F. Frerichs, Jens Sölter, Thomas Lübben, E. Brinksmeier, Hans‐Werner Zoch · 2016

The newly developed concept of Process Signatures enables the comparison of surface integrity achieved by seemingly different manufacturing processes. This paper suggests Process Signatures for grinding and induction heating. Based on fini…

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