Title: 2D high speed machining simulations using a new explicit formulation with linear triangular elements

Authors: P.O. De Micheli, K. Mocellin

Addresses: Centre of Material Forming, CEMEF, MINES Paris Tech, 1 rue claude Daunesse, 06904 Sophia Antipolis CEDEX, France. ' Centre of Material Forming, CEMEF, MINES Paris Tech, 1 rue claude Daunesse, 06904 Sophia Antipolis CEDEX, France

Abstract: This paper presents the several advantages of a new explicit formulation using modified linear tetrahedral elements non-sensitive to volumetric locking in the scope of high speed machining simulations. First, the explicit time integration allows obtaining very interesting computational time in very dynamic cases with complex behaviour laws. Then, the use of a tetrahedral mesh permits to use robust non-structured adaptive remeshers too. No chip separation criteria or damage model is used. Our 2D orthogonal cutting model detects automatically the apparition of an adiabatic shear band, and simulates very precisely its evolution and the chip formation. Phenomena relative to adiabatic shearing bands already described in the literature can be observed in detail in the simulation. This model is a powerful tool to improve the understanding of chip formation and adiabatic shear band propagation, and to simplify the optimisation of high speed machining processes in industries.

Keywords: high speed machining; adiabatic shear bands; thermo-elasto-visco-plasticity; explicit FEM; finite element method; modelling; linear tetrahedra; linear triangular elements; simulation; orthogonal cutting; chip formation.

DOI: 10.1504/IJMMM.2011.039651

International Journal of Machining and Machinability of Materials, 2011 Vol.9 No.3/4, pp.266 - 281

Published online: 13 Apr 2011 *

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