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Thesis - PhD - Dattatraya Parle - IIT Bombay - 3.1 Numerical modeling of micro-cutting process

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Chapter 3

Numerical Modeling of Orthogonal Micro-Cutting

3.1 Numerical modeling of micro-cutting process

In recent years, FEA has become the main tool for simulating orthogonal micro-cutting processes since its first use in 1970’s. Since then there has been a tremendous increase in the use of FEA in modeling micro-cutting. A concise literature review of historical developments along with major research work in machining processes using FEA has been presented by Soo [92] and Mackerle [93-94].

Fig. 3.1 shows two different time integration techniques i.e. explicit and implicit used in numerical modeling and simulation of micro-cutting processes. The implicit method solves a set of finite element equations by performing iterations until a convergence criterion is achieved for each time step increment. On the other hand, the explicit approach determines the solution to the set of finite element equations by using a central difference method (CDM) to integrate the equations of motion through time. Researchers used both implicit and explicit methods in the numerical simulation of cutting processes. They also elaborated on the use of implicit or explicit techniques [95-98]. In general, a review of literature shows that the simulation of micro-cutting uses various numerical formulations, they are:

·       Lagrangian formulation,

·       Eulerian formulation,

·       Arbitrary Lagrangian-Eulerian (ALE) formulation, and

·       Smoothed Particle Hydrodynamics (SPH) formulation.

With the rapid growth of various commercial frameworks, modeling of the cutting process can be readily achieved to understand complex phenomena of micro-cutting. Until late 1990, numerous researchers used their own codes. However of late, the use of commercially available software packages have increased dramatically, which includes NIKE-2D, FORGE2, ANSYS, LS-DYNA, DEFORM, ABAQUS, MSC.MARC, and AdvantEdge.

Literature review reveals that micro-cutting processes can be simulated using various finite element formulations such as Lagrangian [97-100], Eulerian [101], Arbitrary Lagrangian-Eulerian (ALE) [102-104], and Smoothed Particle Hydrodynamics (SPH) [105-109] within these commercial software frameworks. Evidently, choosing a suitable finite element formulation to simulate micro-cutting in two- or three-dimensions can be difficult as each one has its own pros and cons, as summarized in Fig 3.1. Based on the above review, in the present work, structural-thermal coupled simulations have been performed using Lagrangian formulation to study microcrack and gross fracture phenomenon, whereas the SPH formulation has been used to model the workpiece microstructure within LS-DYNA framework.

3.2 FEA simulation of micro-cutting using Lagrangian formulation

3.3 Microstructure modeling using SPH formulation

3.4 Summary