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Modeling Grinding Processes-Mesh or Mesh-Free Methods, 2D or 3D Approach?
TU Kaiserslautern, Erwin-Schrödinger-Straße, D-67653 Kaiserslautern, Germany.ORCID iD: 0000-0002-3146-8904
Luleå University of Technology, Department of Engineering Sciences and Mathematics, Solid Mechanics. Escuela de Ciencias Aplicadas e Ingeniería, Universidad EAFIT, Cra 49 n 7-sur-50, Medellín 050022, Colombia.ORCID iD: 0000-0003-3865-1426
TU Kaiserslautern, Erwin-Schrödinger-Straße, D-67653 Kaiserslautern, Germany.ORCID iD: 0000-0003-4358-1960
2022 (English)In: Journal of Manufacturing and Materials Processing, E-ISSN 2504-4494, Vol. 6, no 5, article id 120Article in journal (Refereed) Published
Abstract [en]

The objectives of this study are mainly two: (1) to validate whether a single grain scratch process can be modeled in two dimensions under the assumption of plane strain, and (2) to select the best discretization approach to model a single grain scratch process. This paper first focuses on the simulation of the orthogonal cutting process (aluminum alloy A2024 T351) using two mesh-based discretization approaches, the pure Lagrangian method (LAG) and the arbitrary Lagrangian-Eulerian method (ALE), and two particle-based approaches, the particle finite element method (PFEM) and smooth particle hydrodynamics (SPH), for both positive and negative rake angles. Benchmarking of the orthogonal cutting models at a rake angle of gamma = 20 degrees is performed with the results of the process forces (cutting and passive forces) of a turning experiment from the literature. It is shown that all models are able to predict the cutting forces, but not the passive force. The orthogonal cutting model is further extended to simulate the cutting mechanism with negative rake tool geometries typically found in grinding and single grit scratching processes. The effects of the negative rake angles on the discretization approaches are studied. The calculated process forces are also compared to the measurements of the single grit scratch process performed at our laboratory. The 2D orthogonal cutting models significantly overestimate the process forces. One of the reasons why the orthogonal 2D cutting model is inadequate is that it cannot describe the complex mechanisms of material removal such as rubbing, plowing, and cutting. To account for these phenomena in LAG, ALE, and SPH discretization approaches, a 3D scratch model is developed. When comparing the process forces of the 3D model with the experimental measurements, all three discretization approaches show good agreement. However, it can be seen that the ALE model most closely matches the process forces with the experimental results. Finally, the ALE 3D scratch model was subjected to sensitivity analysis by changing the cutting speed, the depth of cut and the tool geometry. The results clearly show that the ALE method not only predicts the process forces and form the trends observed in the scratching experiments, but also predicts the scratch topography satisfactorily. Hence, we conclude that a 3D model is necessary to describe a scratch process and that the ALE method is the best discretization method.

Place, publisher, year, edition, pages
MDPI , 2022. Vol. 6, no 5, article id 120
Keywords [en]
finite element method, arbitrary Lagrangian-Eulerian, particle finite element method, smooth particle hydrodynamics, orthogonal cutting, oblique cutting, single grit scratch
National Category
Applied Mechanics
Research subject
Solid Mechanics
Identifiers
URN: urn:nbn:se:ltu:diva-94016DOI: 10.3390/jmmp6050120ISI: 000872843900001Scopus ID: 2-s2.0-85140634140OAI: oai:DiVA.org:ltu-94016DiVA, id: diva2:1711213
Note

Validerad;2022;Nivå 2;2022-11-16 (hanlid);

Funder: German Research Foundation, DFG (252408385)

Available from: 2022-11-16 Created: 2022-11-16 Last updated: 2023-09-05Bibliographically approved

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Rodríguez Prieto, Juan Manuel

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