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  • 1.
    Holmberg, Jonas
    et al.
    Swerea IVF AB.
    Rodriguez Prieto, Juan Manuel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Berglund, Johan
    Swerea IVF AB.
    Svoboda, Ales
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Experimental and PFEM-simulations of residual stresses from turning tests of a cylindrical Ti-6Al-4V shaft2018In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 71, p. 144-149Article in journal (Refereed)
    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.

  • 2.
    Larsson, Simon
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Carbonell, Josep Maria
    Centre Internacional de Mètodes Numèrics en Enginyeria (CIMNE) Universitat Politècnica de Catalunya (UPC).
    Rodriguez Prieto, Juan Manuel
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Gustafsson, Gustaf
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Häggblad, Hans-åke
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Celigueta, Miquel Angel
    Centre Internacional de Mètodes Numèrics en Enginyeria (CIMNE) Universitat Politècnica de Catalunya (UPC).
    Latorre, Salvador
    Centre Internacional de Mètodes Numèrics en Enginyeria (CIMNE) Universitat Politècnica de Catalunya (UPC).
    Numerical simulation and validation of powder filling using particle based methods2017In: PARTICLES 2017, 2017Conference paper (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.

  • 3.
    Rodriguez, Juan Manuel
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Carbonell, Josep Maria
    International Center for Numerical Methods in Engineering (CIMNE), Campus Nord UPC, Gran Capitán, s/n., 08034 Barcelona.
    Cante, J.C.
    Escola Tècnica Superior d’Enginyeries Industrial i Aeronàutica de Terrassa.
    Oliver, J.
    International Center for Numerical Methods in Engineering (CIMNE), Campus Nord UPC, Gran Capitán, s/n., 08034 Barcelona.
    Continuous chip formation in metal cutting processes using the Particle Finite Element Method (PFEM)2017In: International Journal of Solids and Structures, ISSN 0020-7683, E-ISSN 1879-2146, Vol. 120, p. 81-102Article in journal (Refereed)
    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.

  • 4.
    Rodriguez, Juan Manuel
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Svoboda, Ales
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    A particle finite element method applied to modeling and simulation of machining processes2017In: Advanced Machining Processes: Innovative Modeling Techniques / [ed] Angelos P. Markopoulos, J. Paulo Davim, Boca Raton: CRC Press, 2017, 1 ed, p. 1-24Chapter in book (Refereed)
    Abstract [en]

    Metal cutting process is a nonlinear dynamic problem that includesgeometrical, material, and contact nonlinearities. In this work, aLagrangian finite element approach for the simulation of metal cuttingprocess is presented based on the so-called particle finite element method(PFEM). The governing equations for the deformable bodies are discretizedwith the finite element method (FEM) via a mixed formulationusing simplicial elements with equal linear interpolation for displacements,pressure, and temperature. The use of PFEM for modeling ofmetal cutting processes includes the use of a remeshing process, α-shapeconcepts for detecting domain boundaries, contact mechanics laws, andmaterial constitutive models. In this chapter, a 2D PFEM-based numericalmodeling of metal cutting processes has been studied to investigate theeffects of cutting velocity on tool forces, temperatures, and stresses inmachining of Ti–6Al–4V. The Johnson–Cook plasticity model is usedto describe the work material behavior. Numerical simulations are inagreement with experimental results.

  • 5.
    Rodriguez, Juan Manuel
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Svoboda, Ales
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Dislocation Density Based Material Model Applied in PFEM-simulation of Metal Cutting2017In: Procedia CIRP, ISSN 2212-8271, E-ISSN 2212-8271, Vol. 58, p. 193-197Article in journal (Refereed)
    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.

  • 6.
    Rodriguez Prieto, J. M.
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Carbonell, J. M.
    International Center for Numerical Methods in Engineering (CIMNE), Barcelona, Spain.
    Cante, J.C.
    Escola Tècnica Superior d’Enginyeries Industrial i Aeronàutica de Terrassa; International Center for Numerical Methods in Engineering (CIMNE), Barcelona, Spain.
    Oliver, J.
    E.T.S dEnginyers de Camins, Canals i Ports, Technical University of Catalonia (BarcelonaTech), Barcelona, Spain. International Center for Numerical Methods in Engineering (CIMNE), Barcelona, Spain.
    Jonsén, P.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Generation of segmental chips in metal cutting modeled with the PFEM2018In: Computational Mechanics, ISSN 0178-7675, E-ISSN 1432-0924, Vol. 61, no 6, p. 639-655Article in journal (Refereed)
    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.

  • 7.
    Rodriguez Prieto, Juan Manuel
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Carbonell, J.M
    International Center for Numerical Methods in Engineering (CIMNE), Campus Nord UPC, Barcelona, Spain.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Numerical Methods for the Modelling of Chip Formation2019In: Archives of Computational Methods in Engineering, ISSN 1134-3060, E-ISSN 1886-1784Article in journal (Refereed)
    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.

  • 8.
    Rodriguez Prieto, Juan Manuel
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Svoboda, Ales
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    A Particle Finite Element Method for Machining Simulations2016In: 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 (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.

  • 9.
    Rodriguez Prieto, Juan Manuel
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Svoboda, Ales
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Numerical modeling of metal cutting processes using the particle finite element method (PFEM) and a physically based plasticity model2015In: 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 (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.

  • 10.
    Rodriguez Prieto, Juan Manuel
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Svoboda, Ales
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    On the Numerical Modeling of Metal Forming Processes Using the Particle Finite Elementmethod2016In: 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 (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.

  • 11.
    Rodriguez Prieto, Juan Manuel
    et al.
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Jonsén, Pär
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Svoboda, Ales
    Luleå University of Technology, Department of Engineering Sciences and Mathematics, Mechanics of Solid Materials.
    Simulation of metal cutting using the particle finite-element method and a physically based plasticity model2017In: Computational Particle Mechanics, ISSN 2196-4378, Vol. 4, no 1, p. 35-51Article in journal (Refereed)
    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.

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