TY - JOUR

T1 - Numerical methods for the simulation of segmented chips and experimental validation in machining of ti-6al-4v

AU - Menze, C.

AU - Wegert, R.

AU - Reeber, T.

AU - Erhardt, F.

AU - Möhring, H. C.

AU - Stegmann, J.

AU - Kabelac, S.

N1 - Funding Information: cooling, lubrication and transportation – coupled mechanical and fluid-dynamical simulation methods for efficient production processes (FLUSIMPRO)” (SPP 2231) funded by the German Research Foundation (DFG) is dedicated to the investigation and simulation of these complex thermomechanical and thermofluid interactions. In the first project period, the machining process and the flow situation are studied separately as submodels. Later, the submodels will be coupled with each other to investigate the interaction of cooling, lubrication, and transportation. The work presented here illustrates the investigation of the part model of simulation the chip formation. The simulation of machining processes by discretising the continuum through finite elements is a well-researched area in general. However, the simulation of chip removal still poses problems. Extremely distorted elements and element deletions contribute to unstable simulations and noisy analysis results. The increasingly emerging mesh-free particle-based In addition, most production processes, especially machining simulation methods hold great potential to machining of high-strength materials such as titanium and neutralise the chip removal problem [Heisel, 2013; Rana, titanium alloys, are usually carried out in combination with 2019]. However, to make a qualitative statement about the liquid cooling lubricants. This increases the degree of resulting parts, they require a large quantity of particles, which are computationally expensive. A consideration of mesh-based approaches is still useful because they provide good information about the evolving geometries with less effort.

PY - 2021/11

Y1 - 2021/11

N2 - The simulation of machining processes holds the opportunity for process improvement on many levels. Possible benefits that can be derived from accurate representations of the real processes on the tool from simulations include a prediction of tool wear, the shape of the chips produced, the forces, frictions and temperatures that arise and the residual stresses in the workpiece. These predictions can be used to improve the process in terms of its economic and ecological behaviour: Increasing the service life of the tools used through an improved understanding of the tool-workpiece interaction. The finite element method (FEM), among others, has emerged as a common method for simulating these processes. When simulating machining processes using FEM, a major challenge is to avoid or compensate for the mesh distortions caused by the massive, fast-moving deformation processes, but at the same time to allow the mesh to be discretised in some way to ensure chip removal. To this end, various approaches will be presented in the course of this work and the mesh-based approaches will be explored in depth. Among other things, a remeshing approach for these investigations was developed. The machining of TI6AL4V is used to illustrate these approaches, as its tendency to form segmented chips is particularly challenging to model.

AB - The simulation of machining processes holds the opportunity for process improvement on many levels. Possible benefits that can be derived from accurate representations of the real processes on the tool from simulations include a prediction of tool wear, the shape of the chips produced, the forces, frictions and temperatures that arise and the residual stresses in the workpiece. These predictions can be used to improve the process in terms of its economic and ecological behaviour: Increasing the service life of the tools used through an improved understanding of the tool-workpiece interaction. The finite element method (FEM), among others, has emerged as a common method for simulating these processes. When simulating machining processes using FEM, a major challenge is to avoid or compensate for the mesh distortions caused by the massive, fast-moving deformation processes, but at the same time to allow the mesh to be discretised in some way to ensure chip removal. To this end, various approaches will be presented in the course of this work and the mesh-based approaches will be explored in depth. Among other things, a remeshing approach for these investigations was developed. The machining of TI6AL4V is used to illustrate these approaches, as its tendency to form segmented chips is particularly challenging to model.

KW - ALE

KW - CEL

KW - Element deletion

KW - FEM

KW - Machining

KW - Orthogonal cutting

KW - Remeshing

UR - http://www.scopus.com/inward/record.url?scp=85119065407&partnerID=8YFLogxK

U2 - 10.17973/MMSJ.2021_11_2021152

DO - 10.17973/MMSJ.2021_11_2021152

M3 - Article

AN - SCOPUS:85119065407

VL - 2021

SP - 5052

EP - 5060

JO - MM Science Journal

JF - MM Science Journal

SN - 1803-1269

M1 - HSM2021-2021152

ER -