A Sensibility Analysis to Geometric and Cutting Conditions Using the Particle Finite Element Method (PFEM)

Rodríguez, Juan Manuel Corchado; Arrazola, P.J.; Cante, Juan; Kortabarria, Aitor; Oliver, J.

doi:10.1016/j.procir.2013.06.073

Cited by 11 publications

(5 citation statements)

References 6 publications

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“…Although PFEM was initially applied to problems in the field of fluid mechanics, it is being currently applied to a wide range of simulation problems [6][7][8][9]: filling, erosion, mixing processes, thermoviscous processes and thermal diffusion problems, among others. First applications of PFEM to solid mechanics are found in [10][11][12][13][14][15] to problems involving large strains and rotations, multibody contacts and creation of new surfaces (riveting, powder filling, and machining).…”

Section: The Particle Finite-element Methodsmentioning

confidence: 99%

Simulation of metal cutting using the particle finite-element method and a physically based plasticity model

2016

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Metal cutting is one of the most common metalshaping 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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Section: The Particle Finite-element Methodsmentioning

confidence: 99%

Simulation of metal cutting using the particle finite-element method and a physically based plasticity model

2016

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“…The finite surface mesh is denoted by ( ) , i j and the subscript 1 2 presents the value of the displacement at the boundary of the control surface (see Figure 2). Based on the above relations at the adjacent locations the Equation (4) 0. 5 3 10 , , , , 2 , 8 8 8 6 5 3 , , ,…”

Section: Finite Volume Formulationmentioning

confidence: 99%

“…Keyvan et al [3] analyzed the effective geometry of the cutting edge prior to cutting by employing the circular regression method. A sensibility analysis to geometric and cutting conditions was carried out by Rodrigues et al employing particle finite element method [4], and the influence of cutting parameters on cutting forces generated during the turning of aluminium alloy (UNS A97075) work pieces was studied by Agustina et al [5].…”

Section: Introductionmentioning

confidence: 99%

Application of FVM Analysis for Elastic Characteristics on Cutting Process of a Composited Coating Iron

Go¹,

Lee²

2014

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A composite material as a work piece is taken into account to investigate the elastic characteristics displaying during the cutting process. The magnitude of the elastic behaviors such as displacements and stresses reacts sensitively to the cutting angle and the vertical force increase, and the magnitude increases along the increments of the cutting angle and the vertical force increase. The buffering mechanism at the bond coat is described well by the fluctuation phenomenon for the horizontal displacement distribution profiles at the substrate. The variation of cutting angle under high vertical force yields profound influence on the behaviors of the longitudinal stress and the shear stress.

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“…In addition, these simulations provide some invaluable information, such as stresses, strains, strain rates, and temperature gradients, that are otherwise very difficult to determine through experimental investigations [1,20,21]. Several studies on numerical simulations of machining processes under orthogonal cutting conditions and assuming plane strains were found in the literature [22][23][24][25][26]. Most of these simulations were performed using mesh-based methods; however, these simulations are prone to mesh distortions that can potentially lead to simulation failures.…”

Section: Introductionmentioning

confidence: 99%

Modeling Grinding Processes—Mesh or Mesh-Free Methods, 2D or 3D Approach?

Sridhar

Prieto

Payrebrune

2022

JMMP

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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 γ=20∘ 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.

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A Sensibility Analysis to Geometric and Cutting Conditions Using the Particle Finite Element Method (PFEM)

Cited by 11 publications

References 6 publications

Simulation of metal cutting using the particle finite-element method and a physically based plasticity model

Simulation of metal cutting using the particle finite-element method and a physically based plasticity model

Application of FVM Analysis for Elastic Characteristics on Cutting Process of a Composited Coating Iron

Modeling Grinding Processes—Mesh or Mesh-Free Methods, 2D or 3D Approach?

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