3D finite element modelling of drilling: The effect of modelling method

Priest, Joshua; Ghadbeigi, Hassan; Avar-Soberanis, Sabino; Gerardis, S.

doi:10.1016/j.cirpj.2021.06.001

Cited by 19 publications

(4 citation statements)

References 31 publications

(44 reference statements)

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“…The element deletion function is mainly utilized to remove the highly distorted elements that prevent reaching convergence in an explicit simulation. This method proved to be highly efficient in the simulation of crashes [22], impacts [23,24], machining [25], and damage evolution in materials [26,27]. Aboutalebi et al [28] utilized a ductile damage model for St12 steel and calibrated its parameters using simple and convenient tensile tests.…”

Section: Figurementioning

confidence: 99%

Development and Implementation of Element Deletion Algorithm into an Open-Source Software Based on the Fracture Locus of Materials

2022

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An accurate fracture simulation is often associated with how reliably the material model is represented. Hence, many models dealing with the calibration of ductile damage of materials have already been developed to predict failure initiation. Nevertheless, the challenge remains in obtaining an accurate representation of the fracture growth. Herein, an element deletion algorithm is developed and implemented into finite element open-source software. The deleted elements are replaced by new cells made of a virtual low-stiffness material. To better visualize the failure progression, the final model excludes these virtual cells from the representation. The functionality of the algorithm is tested through a series of two-dimensional simulations on three different geometries with a well-known behavior under uniaxial tension. Moreover, the failure response of a three-dimensional lattice structure is numerically investigated and compared against experimental data. The results of the two-dimensional simulations showed the capability of the algorithm to predict the onset of failure, crack nucleation, and fracture growth. Similarly, the onset and the initial fracture region were accurately captured in the three-dimensional case, with some convergence issues that prevent the visualization of the fracture growth. Overall, the results are encouraging, and the algorithm can be improved to introduce other computational functionalities.

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Section: Figurementioning

confidence: 99%

Development and Implementation of Element Deletion Algorithm into an Open-Source Software Based on the Fracture Locus of Materials

2022

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“…Ensuring the quality of produced metal parts in terms of surface integrity and geometrical accuracy while simultaneously ensuring a long tool life are vital for the future of subtractive manufacturing; thus, a more comprehensive understanding of cutting mechanics is necessary to meet these evolving demands [1,2]. Therefore, the Finite Element Method (FEM) of machining processes has received much attention by numerous researchers in the last decades [3].…”

Section: Introductionmentioning

confidence: 99%

A Data-Driven Approach for Cutting Force Prediction in FEM Machining Simulations Using Gradient Boosted Machines

Reeber,

Wolf,

Möhring

2024

JMMP

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Cutting simulations via the Finite Element Method (FEM) have recently gained more significance due to ever increasing computational performance and thus better resulting accuracy. However, these simulations are still time consuming and therefore cannot be deployed for an in situ evaluation of the machining processes in an industrial environment. This is due to the high non-linear nature of FEM simulations of machining processes, which require considerable computational resources. On the other hand, machine learning methods are known to capture complex non-linear behaviors. One of the most widely applied material models in cutting simulations is the Johnson–Cook material model, which has a great influence on the output of the cutting simulations and contributes to the non-linear behavior of the models, but its influence on cutting forces is sometimes difficult to assess beforehand. Therefore, this research aims to capture the highly non-linear behavior of the material model by using a dataset of multiple short-duration cutting simulations from Abaqus to learn the relationship of the Johnson–Cook material model parameters and the resulting cutting forces for a constant set of cutting conditions. The goal is to shorten the time to simulate cutting forces by encapsulating complex cutting conditions in dependence of material parameters in a single model. A total of five different models are trained and the performance is evaluated. The results show that Gradient Boosted Machines capture the influence of varying material model parameters the best and enable good predictions of cutting forces as well as deliver insights into the relevance of the material parameters for the cutting and thrust forces in orthogonal cutting.

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“…When thermal form errors are of interest the drilling process is usually not modeled in detail, as in e.g. [3] since the computations are too cumbersome. Usually, only a short time interval can be simulated and therefore it is usually not possible to study the complete drilling process.…”

Section: Introductionmentioning

confidence: 99%

3D-Simulation of Heat Flow in Indexable Drilling

Andersson,

Svensson,

Lassila

et al. 2023

KEM

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In machining, the heat flow into the workpiece during the cutting process is often a major concern. The temperature rise can lead to substantial residual stresses or elastic in-process deformations which may result in the dimensional tolerance requirements being violated. In the present study a modelling strategy is developed for determination of the heat load during indexable drilling. The heat load on the workpiece is determined from 3D thermomechanical Coupled Eulerian Lagrangian analyses of orthogonal turning for various chip thicknesses and cutting speeds. The determined heat load is then transferred to a 3D transient heat transfer analysis of the indexable drilling process for the determination of the temperature field. Thereby, this modelling technique avoids the complex cutting process that is performed in real cutting simulations and thereby reducing the computational complexity of the problem considerably. The simulated temperatures are compared with experimentally measured temperatures and some conclusions are drawn regarding the modelling approach.

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3D finite element modelling of drilling: The effect of modelling method

Cited by 19 publications

References 31 publications

Development and Implementation of Element Deletion Algorithm into an Open-Source Software Based on the Fracture Locus of Materials

Development and Implementation of Element Deletion Algorithm into an Open-Source Software Based on the Fracture Locus of Materials

A Data-Driven Approach for Cutting Force Prediction in FEM Machining Simulations Using Gradient Boosted Machines

3D-Simulation of Heat Flow in Indexable Drilling

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