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Discretisation and error analysis for a mathematical model of milling processes
We investigate a mathematical model for milling where the cutting tool dynamics is considered together with an elastic workpiece model. Both are coupled by the cutting forces consisting of two dynamic components representing vibrations of the tool and of the workpiece, respectively, at the present and previous tooth periods. We develop a numerical solution algorithm and derive error estimates both for the semi-discrete and the fully discrete numerical scheme. Numerical computations in the last section support the analytically derived error estimates.
Local surrogate responses in the Schwarz alternating method for elastic problems on random voided domains
Imperfections and inaccuracies in real technical products often influence the mechanical behavior and the overall structural reliability. The prediction of real stress states and possibly resulting failure mechanisms is essential and a real challenge, e.g. in the design process. In this contribution, imperfections in elastic materials such as air voids in adhesive bonds between fiber-reinforced composites are investigated. They are modeled as arbitrarily shaped and positioned. The focus is on local displacement values as well as on associated stress concentrations caused by the imperfections. For this purpose, the resulting complex random one-scale finite element model is numerically solved by a new developed surrogate model using an overlapping domain decomposition scheme based on Schwarz alternating method. Here, the actual response of local subproblems associated with isolated material imperfections is determined by a single appropriate surrogate model, that allows for an accelerated propagation of randomness. The efficiency of the method is demonstrated for imperfections with elliptical and ellipsoidal shape in 2D and 3D and extended to arbitrarily shaped voids. For the latter one, a local surrogate model based on artificial neural networks (ANN) is constructed. Finally, a comparison to experimental results validates the numerical predictions for a real engineering problem.
Optimal control for the thermistor problem
This paper is concerned with the state-constrained optimal control of the two-dimensional thermistor problem, a quasi-linear coupled system of a parabolic and elliptic PDE with mixed boundary conditions. This system models the heating of a conducting material by means of direct current. Existence, uniqueness and continuity for the state system are derived by employing maximal elliptic and parabolic regularity. By similar arguments the linearized state system is discussed, while the adjoint system involving measures is investigated using a duality argument. These results allow to derive first-order necessary conditions for the optimal control problem.
Simulationsbasierte Regelung der Laserhärtung von Stahl
Bei der Oberflaechenhärtung mit Hilfe von Laserstrahlen ist eine konstante Einhärtetiefe erwünscht, wobei gleichzeitig Anschmelzungen vermieden werden sollen. Um Anschmelzungen zu verhindern, kann die Temperatur im Auftreffpunkt des Lasers gemessen werden und die Laserleistung entsprechend geregelt werden. Eine konstante Temperatur fährt bei geometrisch komplizierten Bauteilen jedoch nicht zu einer konstanten Einhärtetiefe. In dieser Arbeit wird ein Verfahren aufgezeigt, wobei durch numerische Simulationen eine nichtkonstante Oberflächentemperatur berechnet wird, die eine konstante Einhärtetiefe liefert. Die berechnete Oberflächentemperatur kann als Solltemperatur im realen Prozess benutzt werden.
Optimal control of a cooling line for production of hot rolled dual phase steel
In this article, the optimal control of a cooling line for production of dual phase steel in a hot rolling process is discussed. In order to achieve a desired dual phase steel microstructure an optimal cooling strategy has to be found. The cooling strategy should be such that a desired final distribution of ferrite in the steel slab is reached most accurately. This problem has been solved by means of mathematical control theory. The results of the optimal control of the cooling line have been verified in hot rolling experiments at the pilot hot rolling mill at the Institute for Metal Forming (IMF), TU Bergakademie Freiberg.
Weak entropy solutions to a model in induction hardening, existence and weak-strong uniqueness
In this paper, we investigate a model describing induction hardening of steel. The related system consists of an energy balance, an ODE for the different phases of steel, and Maxwell's equations in a potential formulation. The existence of weak entropy solutions is shown by a suitable regularization and discretization technique. Moreover, we prove the weak-strong uniqueness of these solutions, i.e., that a weak entropy solutions coincides with a classical solution emanating form the same initial data as long as the classical one exists. The weak entropy solution concept has advantages in comparison to the previously introduced weak solutions, e.g., it allows to include free energy functions with low regularity properties corresponding to phase transitions.
Comparison of monomorphic and polymorphic approaches for uncertainty quantification with experimental investigations
Unavoidable uncertainties due to natural variability, inaccuracies, imperfections or lack of knowledge are always present in real world problems. To take them into account within a numerical simulation, the probability, possibility or fuzzy set theory as well as a combination of these are potentially usable for the description and quantification of uncertainties. In this work, different monomorphic and polymorphic uncertainty models are applied on linear elastic structures with non-periodic perforations in order to analyze the individual usefulness and expressiveness. The first principal stress is used as an indicator for structural failure which is evaluated and classified. In addition to classical sampling methods, a surrogate model based on artificial neural networks is presented. With regard to accuracy, efficiency and resulting numerical predictions, all methods are compared and assessed with respect to the added value. Real experiments of perforated plates under uniaxial tension are validated with the help of the different uncertainty models.
Task assignment, sequencing and path-planning in robotic welding cells
A workcell composed of a workpiece and several welding robots is considered. We are interested in minimizing the makespan in the workcell. Hence, one needs i) to assign tasks between the robots, ii) to do the sequencing of the tasks for each robot and iii) to compute the fastest collisionfree paths between the tasks. Up to now, task assignment and path-planning were always handled separately, the former being a typical Vehicle Routing Problem whereas the later is modelled using an optimal control problem. In this paper, we present a complete algorithm which combines discrete optimization techniques with collision detection and optimal control problems efficiently
Identification of the thermal growth characteristics of coagulated tumor tissue in laser-induced thermotherapy
We consider an inverse problem arising in laser-induced thermotherapy, a minimally invasive method for cancer treatment, in which cancer tissues is destroyed by coagulation. For the dosage planning numerical simulation play an important role. To this end a crucial problem is to identify the thermal growth kinetics of the coagulated zone. Mathematically, this problem is a nonlinear and nonlocal parabolic heat source inverse problem. The solution to this inverse problem is defined as the minimizer of a nonconvex cost functional. The existence of the minimizer is proven. We derive the Gateaux derivative of the cost functional, which is based on the adjoint system, and use it for a numerical approximation of the optimal coefficient.
Development of a stability prediction tool for the identification of stable milling processes
This paper deals with a new mathematical model to characterise the interaction between machine and work piece in a milling process. The model consists of a multi-body system representing the milling machine and a linear thermo-elastic work piece model. An extensive experimental analysis supported the development of the governing model equations. A numerical solution strategy is outlined and complemented by simulations of stable and unstable milling processes including work piece effects. The last part covers the development of a new algorithm for the stability analysis of large milling systems.