Technical Paper
Virtual Chip Test and Washer Simulation for Machining Chip Cleanliness Management Using Particle-Based CFD
2024-04-09
2024-01-2730
Metal cutting/machining is a widely used manufacturing process for producing high-precision parts at a low cost and with high throughput. In the automotive industry, common engine components such as cylinder heads or cylinder blocks are all manufactured using such processes. Despite its cost benefits, manufacturers often face the problem of machining chips and cutting oil residue remaining on the finished surface after machining operations, and these wastes can be very difficult to clean. While part cleaning/washing equipment suppliers often claim that their washers have superior performance, determining the washing efficiency is challenging without knowledge of chip clogging locations and water jet flow patterns. In this paper, a virtual engineering methodology using particle-based CFD is developed to manage the metal chip cleanliness issue resulting from engine component machining operations. This methodology comprises two simulation methods.