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. 2018;61(6):639-655.
doi: 10.1007/s00466-017-1442-z. Epub 2017 Sep 1.

Generation of segmental chips in metal cutting modeled with the PFEM

J M Rodriguez Prieto  1 , J M Carbonell  2 , J C Cante  3   2 , J Oliver  4   2 , P Jonsén  1
Affiliations

Generation of segmental chips in metal cutting modeled with the PFEM

J M Rodriguez Prieto et al. Comput Mech. 2018.

Abstract

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.

Keywords: Metal cutting processes; Particle Finite Element Method (PFEM); Serrated chip formation.

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Figures

Fig. 1
Fig. 1
Linear cutting test model
Fig. 2
Fig. 2
Rigid tool definition parameters and contact zones. Contact zones defined by the intersection of the groups depicted in Fig. 3
Fig. 3
Fig. 3
Geometrical contact search based on the definition of spatial rigid tool contact zones
Fig. 4
Fig. 4
Remeshing steps in a standard PFEM numerical simulation
Fig. 5
Fig. 5
Three main criteria to add a new particle
Fig. 6
Fig. 6
Three main criteria to remove a particle
Fig. 7
Fig. 7
Sequence of refinement for a simulation of linear cutting test. Percentage of the mean error on the equivalent plastic strain value depicted on particles
Fig. 8
Fig. 8
Comparison of chip morphologies of Ti6Al4V at different cutting speeds (temperature in Kelvins (K) )
Fig. 9
Fig. 9
Comparison of chip morphologies of Ti6Al4V at different cutting speeds (temperature in Kelvins (K) )
Fig. 10
Fig. 10
Comparison of chip morphologies of Ti6Al4V at different cutting speeds (temperature in Kelvins (K) )
Fig. 11
Fig. 11
Cutting forces of Ti6Al4V at different cutting speeds
Fig. 12
Fig. 12
Cutting forces of Ti6Al4V at different cutting speeds
Fig. 13
Fig. 13
Development of the von Mises stress inside a chip for a cutting speed of 20 m/s (MPa)
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References

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    1. Carbonell JM (2009) Modeling of ground excavation with the particle finite element method. Ph.D. thesis, Universitat Politècnica de Catalunya (UPC), Barcelona

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