Computational techniques applied to high-speed machining under adiabatic strain localization conditions

Owen, D. R. J.; Vaz, M.

doi:10.1016/s0045-7825(98)00220-5

Cited by 59 publications

(42 citation statements)

References 32 publications

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“…A lagrangian formulation was used to simulate complex thermo-mechanical processes in [50,61,81,81] and [25]. The Eulerian formulation is used in [67].…”

Section: Motivationmentioning

confidence: 99%

The particle finite element method (PFEM) in thermo‐mechanical problems

Rodríguez

Carbonell

Cante

et al. 2016

Numerical Meth Engineering

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The aim of this work is to develop a numerical framework for accurately and robustly simulating the different conditions exhibited by thermo-mechanical problems. In particular the work will focus on the analysis of problems involving large strains, rotations, multiple contacts, large boundary surface changes and thermal effects.The framework of the numerical scheme is based on the Particle Finite Element Method (PFEM) in which the spatial domain is continuously redefined by a distinct nodal reconnection, generated by a Delaunay triangulation. In contrast to classical PFEM calculations, in which the free boundary is obtained by a geometrical procedure (α−shape method), in this work the boundary is considered as a material surface, and the boundary nodes are removed or inserted by means of an error function.The description of the thermo-mechanical constitutive model is based on the concepts of large strains plasticity. The plastic flow condition is assumed nearly incompressible, so a u-p mixed formulation, with a stabilization of the pressure term via the Polynomial Pressure Projection (PPP), is proposed.One of the novelties of this work is the use of a combination between the isothermal split (Simo and Miehe [79]) and the so-called IMPL-EX hybrid integration technique (proposed by Oliver, Huespe and Cante [53]) to enhance the robustness and reduce the typical iteration number of the fully implicit NewtonRaphson solution algorithm. * Universitat Politècnica de Catalunya (UPC), Campus Terrassa, C/Colom 11, 08222 Terrassa, Spain.† International Center for Numerical Methods in Engineering (CIMNE), Campus Nord UPC, Gran Capitán, s/n., 08034 Barcelona, Spain. E-mail: cpuigbo@cimne.upc.edu.‡ Escola Tècnica Superior d'Enginyeries Industrial i Aeronàutica de Terrassa, Rambla de Sant Nebridi 22, 08222 Terrassa, Spain.§ International Center for Numerical Methods in Engineering (CIMNE), Campus Nord UPC, Gran Capitán, s/n., 08034 Barcelona, Spain. 2The new set of numerical tools implemented in the PFEM algorithm -including new discretization techniques, the use of a projection of the variables between meshes, and the insertion and removal of points-allows us to eliminate the negative Jacobians present during large deformation problems, which is one of the drawbacks in the simulation of coupled thermo-mechanical problems.Finally, two sets of numerical results in 2D are stated. In the first one, the behavior of the proposed locking free element type and different time integration schemes for thermo-mechanical problems is analyzed. The potential of the method for modeling more complex coupled problems as metal cutting and metal forming processes is explored in the last example.

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“…A lagrangian formulation was used to simulate complex thermo-mechanical processes in [50,61,81,81] and [25]. The Eulerian formulation is used in [67].…”

Section: Motivationmentioning

confidence: 99%

The particle finite element method (PFEM) in thermo‐mechanical problems

Rodríguez

Carbonell

Cante

et al. 2016

Numerical Meth Engineering

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“…Some attempts have been made to account for microstructural transformations of the material, the history of loading, the kinematic and isotropic hardening and the recrystallisation and recovery phenomena [11,13,21]. For example, an interesting phenomenon called strain softening has been introduced in the flow stress model in order to explain the saw-tooth chip formation [5].…”

mentioning

confidence: 99%

“…Owen and Vaz [21] talk about a failure softening phenomenon which induces a decrease in stress with increasing strain. Generally, the failure of a material is a consequence of a dislocation accumulation resulting from a high level of deformation and microscopic damage.…”

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confidence: 99%

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A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V

Calamaz

Coupard

Girot

2008

International Journal of Machine Tools and Manufacture

522

305

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. AbstractA new material constitutive law is implemented in a 2D finite element model to analyse the chip formation and shear localisation when machining titanium alloys. The numerical simulations use a commercial finite element software (FORGE 2005 s ) able to solve complex thermo-mechanical problems. One of the main machining characteristics of titanium alloys is to produce segmented chips for a wide range of cutting speeds and feeds. The present study assumes that the chip segmentation is only induced by adiabatic shear banding, without material failure in the primary shear zone. The new developed model takes into account the influence of strain, strain rate and temperature on the flow stress and also introduces a strain softening effect. The tool chip friction is managed by a combined Coulomb-Tresca friction law. The influence of two different strain softening levels and machining parameters on the cutting forces and chip morphology has been studied. Chip morphology, cutting and feed forces predicted by numerical simulations are compared with experimental results.

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“…The chip formation process in cutting is difficult to analyze using analytical methods, due to that, finite element modeling (FEM) has frequently been used to study the process of chip formation at high cutting speeds, see for example [12,18,25,31]. Numerical modeling of machining processes is continuously attracting researchers for better understanding of chip formation processes, the heat generation in cutting zone, tool-chip inter facial frictional characteristics and quality of the machined surfaces.…”

Section: Introductionmentioning

confidence: 99%

Generation of segmental chips in metal cutting modeled with the PFEM

et al. 2017

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The Particle Finite Element Method, a lagrangian finite element method based on a continuous Delaunay retriangulation 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.B J. M. Carbonell

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Computational techniques applied to high-speed machining under adiabatic strain localization conditions

Cited by 59 publications

References 32 publications

The particle finite element method (PFEM) in thermo‐mechanical problems

The particle finite element method (PFEM) in thermo‐mechanical problems

A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V

Generation of segmental chips in metal cutting modeled with the PFEM

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