Simulation of Cutting processes by the Particle Finite Element Method

Abstract

The cutting process is characterised by large deformations and large configurational changes. Especially the formation of chips and burrs pushes established modeling techniques to their limits. To overcome these difficulties, the particle finite element method (PFEM) combines the benefits of discrete modeling techniques and methods based on continuum mechanics. In this work an outline of the PFEM algorithm is provided and the method is tested in a comparison to the standard finite element method (FEM). The influence of the boundary detection within the PFEM algorithm on the structural integrity of the material is studied and the numerical examples include a tensile test as well as cutting simulations, and parameter studies on important process parameters in cutting.

Adaptive Particle Finite Element Method (A‐PFEM) in Metal Cutting Processes

“…To overcome this difficulty the Particle Finite Element Method (PFEM) which was first introduced in [3] for problems with liquid solid interaction is a promising technique. The main advantage of the PFEM is that boundary can be repeatedly detected thanks to α-shape method [4] and domain be remeshed continuously during the simulation, which enables simulations with large configurational changes [5]. Even though PFEM still have a small flaw to machining processes, because keeping the same number of particles along the numerical simulation is problematic, in some regions of the domain the particles are concentrated meanwhile in other regions the particles moves away.…”

On the Treatment of Plastic Deformation in the Particle Finite Element Method

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The particle finite element method (PFEM) combines the benefits of discrete modeling techniques and approaches based on continuum mechanics. It provides a convenient tool to deal with the problem of large configurational change, such as metal cutting, in which nonlinear plasticity plays a key role [1]. In this article we introduce a phenomenological plasticity model with the help of a multiplicative decomposition of the deformation gradient and an intermediate local configuration into the PFEM framework.

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