Title: Runtime and accuracy issues in three-dimensional finite element simulation of machining

Authors: Chris Fischer

Addresses: Scientific Forming Technologies Corporation, 2545 Farmers Drive Suite 200, Columbus, OH 43235, USA

Abstract: With recent advances in software and hardware technology, the popularity of three-dimensional finite element simulation of metal cutting processes is increasing. However, calculation time still places a major constraint on broader acceptance. Element size is a major factor in determining calculation time and simulation accuracy. This paper compares 2D and 3D simulations of very simple cutting conditions to examine the effect of element size on simulation results. It also examines simulations of two industrial cases, comparing the influence of element size on agreement with experimental results in true three-dimensional processes.

Keywords: FEM; finite element method; 3D simulation; element size; metal cutting.

DOI: 10.1504/IJMMM.2009.026925

International Journal of Machining and Machinability of Materials, 2009 Vol.6 No.1/2, pp.35 - 42

Published online: 09 Jul 2009 *

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