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Rodriguez Prieto, Juan ManuelORCID iD iconorcid.org/0000-0003-3865-1426
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Publications (10 of 10) Show all publications
Rodriguez Prieto, J. M., Carbonell, J. & Jonsén, P. (2019). Numerical Methods for the Modelling of Chip Formation. Archives of Computational Methods in Engineering
Open this publication in new window or tab >>Numerical Methods for the Modelling of Chip Formation
2019 (English)In: Archives of Computational Methods in Engineering, ISSN 1134-3060, E-ISSN 1886-1784Article in journal (Refereed) Epub ahead of print
Abstract [en]

The modeling of metal cutting has proved to be particularly complex due to the diversity of physical phenomena involved, including thermo-mechanical coupling, contact/friction and material failure. During the last few decades, there has been significant progress in the development of numerical methods for modeling machining operations. Furthermore, the most relevant techniques have been implemented in the relevant commercial codes creating tools for the engineers working in the design of processes and cutting devices. This paper presents a review on the numerical modeling methods and techniques used for the simulation of machining processes. The main purpose is to identify the strengths and weaknesses of each method and strategy developed up-to-now. Moreover the review covers the classical Finite Element Method covering mesh-less methods, particle-based methods and different possibilities of Eulerian and Lagrangian approaches.

Place, publisher, year, edition, pages
Springer, 2019
National Category
Applied Mechanics
Research subject
Solid Mechanics
Identifiers
urn:nbn:se:ltu:diva-72672 (URN)10.1007/s11831-018-09313-9 (DOI)
Available from: 2019-01-24 Created: 2019-01-24 Last updated: 2019-01-24
Holmberg, J., Rodriguez Prieto, J. M., Berglund, J., Svoboda, A. & Jonsén, P. (2018). Experimental and PFEM-simulations of residual stresses from turning tests of a cylindrical Ti-6Al-4V shaft. Paper presented at 4th CIRP Conference on Surface Integrity (CSI 2018), Tianjin, China, July 11-13 2018. Procedia CIRP, 71, 144-149
Open this publication in new window or tab >>Experimental and PFEM-simulations of residual stresses from turning tests of a cylindrical Ti-6Al-4V shaft
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2018 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 71, p. 144-149Article in journal (Refereed) Published
Abstract [en]

Alloy Ti-6Al-4V is a frequently used material in aero space applications due the high strength and low weight. This material is however often considered as a difficult to machine alloy due to several material properties such as the inherent characteristics of high hot hardness and strength which is causing an increased deformation of the cutting tool during machining. The thermal properties also cause a low thermal diffusion from locally high temperatures in the cutting zone that allows for reaction to the tool material resulting in increased tool wear.

Predicting the behavior of machining of this alloy is therefore essential when selecting machining tools or machining strategies. If the surface integrity is predicted, the influence of different machining parameters could be studied using Particle Finite Element (PFEM)-simulations. In this investigation the influence from cutting speed and feed during turning on the residual stresses has been measured using x-ray diffraction and compared to PFEM-simulations.

The results showed that cutting speed and feed have great impact on the residual stress state. The measured cutting force showed a strong correlation especially to the cutting feed. The microstructure, observed in SEM, showed highly deformed grains at the surface from the impact of the turning operation and the full width half maximum from the XDR measurements distinguish a clear impact from different cutting speed and feed which differed most for the higher feed rate.

The experimental measurements of the residual stresses and the PFEM simulations did however not correlate. The surface stresses as well as the sign of the residuals stresses differed which might be due to the material model used and the assumption of using a Coulomb friction model that might not represent the cutting conditions in the investigated case.

Place, publisher, year, edition, pages
Elsevier, 2018
National Category
Applied Mechanics Other Materials Engineering
Research subject
Solid Mechanics; Engineering Materials
Identifiers
urn:nbn:se:ltu:diva-69209 (URN)10.1016/j.procir.2018.05.087 (DOI)2-s2.0-85051265926 (Scopus ID)
Conference
4th CIRP Conference on Surface Integrity (CSI 2018), Tianjin, China, July 11-13 2018
Note

Konferensartikel i tidskrift;2018-06-08 (andbra)

Available from: 2018-06-08 Created: 2018-06-08 Last updated: 2018-08-17Bibliographically approved
Rodriguez Prieto, J. M., Carbonell, J. M., Cante, J., Oliver, J. & Jonsén, P. (2018). Generation of segmental chips in metal cutting modeled with the PFEM. Computational Mechanics, 61(6), 639-655
Open this publication in new window or tab >>Generation of segmental chips in metal cutting modeled with the PFEM
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2018 (English)In: Computational Mechanics, ISSN 0178-7675, E-ISSN 1432-0924, Vol. 61, no 6, p. 639-655Article in journal (Refereed) Published
Abstract [en]

The Particle Finite Element Method, a lagrangian finite element method based on a continuous Delaunay re-triangulation of the domain, is used to study machining of Ti6Al4V. In this work the method is revised and applied to study the influence of the cutting speed on the cutting force and the chip formation process. A parametric methodology for the detection and treatment of the rigid tool contact is presented. The adaptive insertion and removal of particles are developed and employed in order to sidestep the difficulties associated with mesh distortion, shear localization as well as for resolving the fine-scale features of the solution. The performance of PFEM is studied with a set of different two-dimensional orthogonal cutting tests. It is shown that, despite its Lagrangian nature, the proposed combined finite element-particle method is well suited for large deformation metal cutting problems with continuous chip and serrated chip formation.

Place, publisher, year, edition, pages
Springer, 2018
National Category
Applied Mechanics
Research subject
Solid Mechanics
Identifiers
urn:nbn:se:ltu:diva-65476 (URN)10.1007/s00466-017-1442-z (DOI)000433223500001 ()
Note

Validerad;2018;Nivå 2;2018-06-01 (rokbeg)

Available from: 2017-09-04 Created: 2017-09-04 Last updated: 2019-03-27Bibliographically approved
Rodriguez, J. M., Carbonell, J. M., Cante, J. & Oliver, J. (2017). Continuous chip formation in metal cutting processes using the Particle Finite Element Method (PFEM). International Journal of Solids and Structures, 120, 81-102
Open this publication in new window or tab >>Continuous chip formation in metal cutting processes using the Particle Finite Element Method (PFEM)
2017 (English)In: International Journal of Solids and Structures, ISSN 0020-7683, E-ISSN 1879-2146, Vol. 120, p. 81-102Article in journal (Refereed) Published
Abstract [en]

This paper presents a study on the metal cutting simulation with a particular numerical technique, the Particle Finite Element Method (PFEM) with a new modified time integration algorithm and incorporating a contact algorithm capability . The goal is to reproduce the formation of continuous chip in orthogonal machining. The paper tells how metal cutting processes can be modelled with the PFEM and which new tools have been developed to provide the proper capabilities for a successful modelling. The developed method allows for the treatment of large deformations and heat conduction, workpiece-tool contact including friction effects as well as the full thermo-mechanical coupling for contact. The difficulties associated with the distortion of the mesh in areas with high deformation are solved introducing new improvements in the continuous Delaunay triangulation of the particles. The employment of adaptative insertion and removal of particles at every new updated configuration improves the mesh quality allowing for resolution of finer-scale features of the solution. The performance of the method is studied with a set of different two-dimensional tests of orthogonal machining. The examples consider, from the most simple case to the most complex case, different assumptions for the cutting conditions and different material properties. The results have been compared with experimental tests showing a good competitiveness of the PFEM in comparison with other available simulation tools.

Place, publisher, year, edition, pages
Elsevier, 2017
National Category
Applied Mechanics
Research subject
Solid Mechanics
Identifiers
urn:nbn:se:ltu:diva-63135 (URN)10.1016/j.ijsolstr.2017.04.030 (DOI)000404199000006 ()2-s2.0-85018253718 (Scopus ID)
Note

Validerad;2017;Nivå 2;2017-06-15 (andbra)

Available from: 2017-04-24 Created: 2017-04-24 Last updated: 2018-07-10Bibliographically approved
Rodriguez, J. M., Jonsén, P. & Svoboda, A. (2017). Dislocation Density Based Material Model Applied in PFEM-simulation of Metal Cutting. Paper presented at 16th CIRP Conference on Modelling of Machining Operations (16th CIRP CMMO), Cluny, France, June 15-16, 2017. Procedia CIRP, 58, 193-197
Open this publication in new window or tab >>Dislocation Density Based Material Model Applied in PFEM-simulation of Metal Cutting
2017 (English)In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 58, p. 193-197Article in journal (Refereed) Published
Abstract [en]

Metal cutting is one of the most common metal-shaping processes. In this process, specified geometrical and surface properties are obtained through the break-up and removal of material by a cutting edge into a chip. The chip formation is associated with large strains, high strain rates and locally high temperatures due to adiabatic heating. These phenomena together with numerical complications make modeling of metal cutting challenging. Material models, which are crucial in metal-cutting simulations, are usually calibrated against data from material testing. Nevertheless, the magnitudes of strains and strain rates involved in metal cutting are several orders of magnitude higher than those generated from conventional material testing. Therefore, a highly desirable feature is a material model that can be extrapolated outside the calibration range. In this study, a physically based plasticity model based on dislocation density and vacancy concentration is used to simulate orthogonal metal cutting of AISI 316L. The material model is implemented into an in-house particle finite-element method software. Numerical simulations are in agreement with experimental results for different cutting speed and feed.

Place, publisher, year, edition, pages
Elsevier, 2017
National Category
Other Materials Engineering Applied Mechanics
Research subject
Solid Mechanics; Engineering Materials
Identifiers
urn:nbn:se:ltu:diva-63646 (URN)10.1016/j.procir.2017.03.338 (DOI)000404958500033 ()2-s2.0-85029766541 (Scopus ID)
Conference
16th CIRP Conference on Modelling of Machining Operations (16th CIRP CMMO), Cluny, France, June 15-16, 2017
Note

2017-06-01 (andbra);Konferensartikel i tidskrift

Available from: 2017-06-01 Created: 2017-06-01 Last updated: 2018-07-10Bibliographically approved
Larsson, S., Carbonell, J. M., Rodriguez Prieto, J. M., Gustafsson, G., Jonsén, P., Häggblad, H.-å., . . . Latorre, S. (2017). Numerical simulation and validation of powder filling using particle based methods. In: PARTICLES 2017: . Paper presented at V International Conference on Particle-based Methods, Fundamentals and Applications, Hannover, Germany, 26-28 September 2017.
Open this publication in new window or tab >>Numerical simulation and validation of powder filling using particle based methods
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2017 (English)In: PARTICLES 2017, 2017Conference paper, Oral presentation with published abstract (Other academic)
Abstract [en]

Powder pressing is a complicated process as the mechanical behaviour of the powder material changes with increasing density. Manufacturers tend to produce components with shapes of increasing complexity requiring improved pressing equipment and methods. Mechanical properties of powder materials changes dramatically from the beginning to the end of the compaction phase. Previous investigations have shown that powder transfer and large powder flow during filling affects the strength of the final component significantly. Combined experimental and numerical studies can improve the understanding of the impact the filling stage has on the final component, e.g. to explain the non-homogeneity of the density of powder pressed parts.This work covers numerical modelling and simulation of powder filling using two different approaches, the discrete element method (DEM) [1,2] which is a micro mechanical based method and the particle finite element method (PFEM) [3] which is a continuum based method. Experimental measurements with digital speckle photography (DSP) [4] from a previous study [5] are used to validate the numerical simulations. The numerical results are compared in terms of agreement with the experimental results, such as velocity- and strain field data. The numerical simulations are further compared in terms of computational efficiency.The comparison of DSP measurements and simulations gives similar flow characteristics. In conclusion, experimental measurements with DSP together with numerical simulation are powerful tools to increase the knowledge of powder filling and also to improve the numerical model prediction. Improved numerical models will facilitate future product development processes and decrease the lead time.

National Category
Applied Mechanics
Research subject
Solid Mechanics
Identifiers
urn:nbn:se:ltu:diva-68990 (URN)
Conference
V International Conference on Particle-based Methods, Fundamentals and Applications, Hannover, Germany, 26-28 September 2017
Available from: 2018-05-30 Created: 2018-05-30 Last updated: 2018-06-07Bibliographically approved
Rodriguez Prieto, J. M., Jonsén, P. & Svoboda, A. (2017). Simulation of metal cutting using the particle finite-element method and a physically based plasticity model (ed.). Computational Particle Mechanics, 4(1), 35-51
Open this publication in new window or tab >>Simulation of metal cutting using the particle finite-element method and a physically based plasticity model
2017 (English)In: Computational Particle Mechanics, ISSN 2196-4378, Vol. 4, no 1, p. 35-51Article in journal (Refereed) Published
Abstract [en]

Metal cutting is one of the most common metal-shaping processes. In this process, specified geometrical and surface properties are obtained through the break-up of material and removal by a cutting edge into a chip. The chip formation is associated with large strains, high strain rates and locally high temperatures due to adiabatic heating. These phenomena together with numerical complications make modeling of metal cutting difficult. Material models, which are crucial in metal-cutting simulations, are usually calibrated based on data from material testing. Nevertheless, the magnitudes of strains and strain rates involved in metal cutting are several orders of magnitude higher than those generated from conventional material testing. Therefore, a highly desirable feature is a material model that can be extrapolated outside the calibration range. In this study, a physically based plasticity model based on dislocation density and vacancy concentration is used to simulate orthogonal metal cutting of AISI 316L. The material model is implemented into an in-house particle finite-element method software. Numerical simulations are in agreement with experimental results, but also with previous results obtained with the finite-element method.

Place, publisher, year, edition, pages
Springer, 2017
National Category
Applied Mechanics Other Materials Engineering
Research subject
Solid Mechanics; Material Mechanics
Identifiers
urn:nbn:se:ltu:diva-3280 (URN)10.1007/s40571-016-0120-9 (DOI)000417457300005 ()2-s2.0-85026434550 (Scopus ID)1162f8b7-aa09-4110-a750-247255072ce5 (Local ID)1162f8b7-aa09-4110-a750-247255072ce5 (Archive number)1162f8b7-aa09-4110-a750-247255072ce5 (OAI)
Available from: 2016-09-29 Created: 2016-09-29 Last updated: 2018-06-05Bibliographically approved
Rodriguez Prieto, J. M., Jonsén, P. & Svoboda, A. (2016). A Particle Finite Element Method for Machining Simulations (ed.). In: (Ed.), M. Papadrakakis; V. Papadopoulos; G. Stefanou; V. Plevris (Ed.), ECCOMAS Congress 2016: VII European Congress on Computational Methods in Applied Sciences and Engineering, Crete Island, Greece, 5–10 June 2016. Paper presented at VII European Congress on Computational Methods in Applied Sciences and Engineering, Crete Island, Greece, 5–10 June 05/06/2016 - 10/06/2016 (pp. 539-553). Athens: National Technical University of Athens, 1
Open this publication in new window or tab >>A Particle Finite Element Method for Machining Simulations
2016 (English)In: ECCOMAS Congress 2016: VII European Congress on Computational Methods in Applied Sciences and Engineering, Crete Island, Greece, 5–10 June 2016 / [ed] M. Papadrakakis; V. Papadopoulos; G. Stefanou; V. Plevris, Athens: National Technical University of Athens , 2016, Vol. 1, p. 539-553Conference paper, Published paper (Refereed)
Abstract [en]

Metal cutting process is a nonlinear dynamic problem that includes geometrical, material, and contact nonlinearities. In this work a Lagrangian finite element approach for simulation of metal cutting processes is presented, based on the so-called Particle Finite Ele-ment Method (PFEM). The governing equations for the deformable bodies are discretized with the FEM via a mixed formulation using simplicial elements with equal linear interpolation for displacements, pressure and temperature. The use of PFEM for modeling of metal cutting pro-cesses includes the use of a remeshing process, α -shape concepts for detecting domain bound-aries, contact mechanics laws and material constitutive models. The merits of the formulation are demonstrated in the solution of 2D and 3D thermally-coupled metal cutting processes using the particle finite element method. The method shows good results and is a promising method for future simulations of thermally/coupled machining processes.

Place, publisher, year, edition, pages
Athens: National Technical University of Athens, 2016
National Category
Applied Mechanics Other Materials Engineering
Research subject
Solid Mechanics; Material Mechanics
Identifiers
urn:nbn:se:ltu:diva-34341 (URN)2-s2.0-84995404839 (Scopus ID)88452a73-5c52-4c19-8e51-43441c87605e (Local ID)88452a73-5c52-4c19-8e51-43441c87605e (Archive number)88452a73-5c52-4c19-8e51-43441c87605e (OAI)
Conference
VII European Congress on Computational Methods in Applied Sciences and Engineering, Crete Island, Greece, 5–10 June 05/06/2016 - 10/06/2016
Note

Godkänd; 2016; 20160606 (parj)

Available from: 2016-09-30 Created: 2016-09-30 Last updated: 2018-06-05Bibliographically approved
Rodriguez Prieto, J. M., Jonsén, P. & Svoboda, A. (2016). On the Numerical Modeling of Metal Forming Processes Using the Particle Finite Elementmethod. In: Ragnar Larsson (Ed.), Proceedings of 29th Nordic Seminar on Computational Mechanics – NSCM29: . Paper presented at 29th Nordic Seminar on Computational Mechanics – NSCM29, Göteborg, Sweden, on October 26-28, 2016. Göteborg: Department of Applied Mechanics CHALMERS UNIVERSITY OF TECHNOLOGY Göteborg, Sweden 2016
Open this publication in new window or tab >>On the Numerical Modeling of Metal Forming Processes Using the Particle Finite Elementmethod
2016 (English)In: Proceedings of 29th Nordic Seminar on Computational Mechanics – NSCM29 / [ed] Ragnar Larsson, Göteborg: Department of Applied Mechanics CHALMERS UNIVERSITY OF TECHNOLOGY Göteborg, Sweden 2016 , 2016, , p. 4Conference paper, Published paper (Refereed)
Abstract [en]

In this work a Lagrangian nite element approach for simulation of metalforming is presented, based on the so-called Particle Finite Element Method (PFEM). Thegoverning equations for the deformable bodies are discretized with the FEM via a mixedformulation using simplicial elements with equal linear interpolation for displacements,pressure and temperature. The use of PFEM for modeling of metal forming processesincludes the use of a remeshing process, -shape concepts for detecting domain boundaries,contact mechanics laws and material constitutive models. The merits of the formulationare demonstrated in the solution of 2D thermally coupled metal forming processes usingthe particle nite element method. The method shows good results and is a promisingmethod for future simulations of thermally/coupled forming processes.

Place, publisher, year, edition, pages
Göteborg: Department of Applied Mechanics CHALMERS UNIVERSITY OF TECHNOLOGY Göteborg, Sweden 2016, 2016. p. 4
Series
Forskningsrapporter : tillämpad mekanik / Chalmers tekniska högskola, ISSN 1652-8549
Keywords
Particle nite element method (PFEM), metal forming. machining, cutting
National Category
Applied Mechanics
Research subject
Solid Mechanics
Identifiers
urn:nbn:se:ltu:diva-60470 (URN)
Conference
29th Nordic Seminar on Computational Mechanics – NSCM29, Göteborg, Sweden, on October 26-28, 2016
Available from: 2016-11-15 Created: 2016-11-15 Last updated: 2018-06-05Bibliographically approved
Rodriguez Prieto, J. M., Jonsén, P. & Svoboda, A. (2015). Numerical modeling of metal cutting processes using the particle finite element method (PFEM) and a physically based plasticity model (ed.). In: (Ed.), E. Oñate; M. Bischoff; D.R.J. Owen; P. Wriggers; T. Zhodi (Ed.), Particle-based Methods IV: Fundamentals and Applications : Proceedings of the IVInternational Conference on Particle-Based Methods–Fundamentals and Applications held in Barcelona, Spain, 28-30September 2015. Paper presented at International Conference on Particle-Based Methods : 28/09/2015 - 30/09/2015 (pp. 1066-1072). Barcelona: International Center for Numerical Methods in Engineering (CIMNE)
Open this publication in new window or tab >>Numerical modeling of metal cutting processes using the particle finite element method (PFEM) and a physically based plasticity model
2015 (English)In: Particle-based Methods IV: Fundamentals and Applications : Proceedings of the IVInternational Conference on Particle-Based Methods–Fundamentals and Applications held in Barcelona, Spain, 28-30September 2015 / [ed] E. Oñate; M. Bischoff; D.R.J. Owen; P. Wriggers; T. Zhodi, Barcelona: International Center for Numerical Methods in Engineering (CIMNE), 2015, p. 1066-1072Conference paper, Published paper (Refereed)
Abstract [en]

Metal cutting is one of the most common metal shaping processes. Specified geometrical and surface properties are obtained by break-up of material and removal by a cutting edge into a chip. The chip formation is associated with large strain, high strain rate and locally high temperature due to adiabatic heating which make the modeling of cutting processes difficult. Furthermore, dissipative plastic and friction work generate high local temperatures. These phenomena together with numerical complications make modeling of metal cutting difficult. Material models, which are crucial in metal cutting simulations, are usually calibrated based on data from material testing. Nevertheless, the magnitude of strain and strain rate involved in metal cutting are several orders higher than those generated from conventional material testing. Therefore, a highly desirable feature is a material model that can be extrapolated outside the calibration range. In this study a physically based plasticity model based on dislocation density and vacancy concentration is used to simulate orthogonal metal cutting of AISI 316L. The material model is implemented into an in-house Particle Finite Element Method software. Numerical simulations are in agreement with experimental results, but also with previous results obtained with the finite element method.

Place, publisher, year, edition, pages
Barcelona: International Center for Numerical Methods in Engineering (CIMNE), 2015
National Category
Applied Mechanics Other Materials Engineering
Research subject
Solid Mechanics; Material Mechanics
Identifiers
urn:nbn:se:ltu:diva-39507 (URN)000380556100097 ()e4af8e04-2a1e-4cb7-a2b2-a64b8a7f5cf9 (Local ID)978-84-944244-7-2 (ISBN)e4af8e04-2a1e-4cb7-a2b2-a64b8a7f5cf9 (Archive number)e4af8e04-2a1e-4cb7-a2b2-a64b8a7f5cf9 (OAI)
Conference
International Conference on Particle-Based Methods : 28/09/2015 - 30/09/2015
Note

Validerad; 2016; Nivå 1; 2016-10-06 (andbra)

Available from: 2016-10-03 Created: 2016-10-03 Last updated: 2018-06-05Bibliographically approved
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ORCID iD: ORCID iD iconorcid.org/0000-0003-3865-1426

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