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Continuous chip formation in metal cutting processes using the Particle Finite Element Method (PFEM)
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
International Center for Numerical Methods in Engineering (CIMNE), Campus Nord UPC, Gran Capitán, s/n., 08034 Barcelona.
Escola Tècnica Superior d’Enginyeries Industrial i Aeronàutica de Terrassa.
International Center for Numerical Methods in Engineering (CIMNE), Campus Nord UPC, Gran Capitán, s/n., 08034 Barcelona.
2017 (English)In: International Journal of Solids and Structures, ISSN 0020-7683, E-ISSN 1879-2146, Vol. 120, 81-102 p.Article 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. Vol. 120, 81-102 p.
National Category
Applied Mechanics
Research subject
Solid Mechanics
Identifiers
URN: urn:nbn:se:ltu:diva-63135DOI: 10.1016/j.ijsolstr.2017.04.030ISI: 000404199000006OAI: oai:DiVA.org:ltu-63135DiVA: diva2:1090507
Note

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

Available from: 2017-04-24 Created: 2017-04-24 Last updated: 2017-08-16Bibliographically approved

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