Abstract
Numerical simulation of laser drilling is rapidly gaining interest in academia and industry since this process remains one of the most important and widely-used technologies in modern manufacturing. Meshfree methods such as Smoothed Particle Hydrodynamics (SPH) have proven to be successful as a numerical tool for the computation of the heat transfer and material removal associated with a laser drilling problem. Nonetheless, the vast majority of recent developments incorporate an inconsistent SPH kernel into their thermal simulations. In this paper, several enhanced schemes are implemented to address this problem by solving the heat transfer more accurately. These meshfree schemes can provide a second-order accurate discretization of the Laplace operator and abolish the inconsistency issue of the standard SPH kernels. An efficient approach is additionally suggested to handle the associated boundary conditions, which relies on the idea of the color function and particle label. The implementation is initially validated by a 3D benchmark study and then applied for the first time to a laser drilling problem.
Highlights
Laser drilling is a manufacturing process where pulsing laser beams are focused on a workpiece to create popped holes
Numerical simulation of laser drilling is rapidly gaining interest in academia and industry since this process remains one of the most important and widely-used technologies in modern manufacturing. Meshfree methods such as Smoothed Particle Hydrodynamics (SPH) have proven to be successful as a numerical tool for the computation of the heat transfer and material removal associated with a laser drilling problem
Reliable computational models are valuable tools for the characterization of quantities that are impossible to predict by theory and/or extremely hard/expensive to measure in experiments. From this point of view, laser drilling problems seem to be a prime candidate for numerical simulation since they are typically involved in ultra-fast pulses and abrupt phase changes [1,2]
Summary
Laser drilling is a manufacturing process where pulsing laser beams are focused on a workpiece to create popped holes ( known as thru-holes). In the article published by Kim [9], Isoparametric Finite Point Interpolation (IPIM) techniques in both weak and strong forms were applied to simulate the material removal process in laser drilling These early studies demonstrated an enormous potential of meshfree methods in simulating laser manufacturing processes. While a growing share of interest in meshfree simulations of laser processing can be noticed upon this literature survey, a comprehensive study of higher order SPH formulations for (3D) thermal modeling in laser-based manufacturing processes seems to be missing from the current state-of-the-art. The ultimate goal is to develop a highly efficient and robust meshfree solver that can provide a design tool for laser-based manufacturing models including all thermal-mechanical-material coupling effects.
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