Abstract
This work presents the development of an explicit/implicit particle finite element method (PFEM) for the 2D modeling of metal cutting processes. The purpose is to study the efficiency of implicit and explicit time integration schemes in terms of precision, accuracy and computing time. The formulation for implicit and explicit time marching schemes is developed, and a detailed study on the explicit solution steps is presented. The PFEM remeshing procedures for insertion and removal of particles have been improved to model the multiple scales of time and/or space of the solution. The detection and treatment of the rigid tool contact are presented for both, implicit and explicit schemes. The performance of explicit/implicit integration is studied with a set of different two-dimensional orthogonal cutting tests of AISI 4340 steel at cutting speeds ranging from 1 m/s up to 30 m/s. It was shown that if the correct selection of the time integration scheme is made, the computing time can decrease up to 40 times. It allows us to affirm that the computing time of the PFEM simulations can be excessive due to the used time marching scheme independently of the meshing process. As a practical result, a set of recommendations to select the time integration schemes for a given cutting speed are given. This is intended to minimize one of the negative constraints pointed out by the industry when using metal cutting simulators.
Highlights
The description of a metal cutting process can be defined by the interaction of two physical elements
Two time integration schemes of the balance equations were implemented within the particle finite element method (PFEM) framework and applied to the numerical modeling of metal cutting processes
The results presented here show that both schemes predicted the same value of stresses, temperature, strain rates and forces
Summary
The description of a metal cutting process can be defined by the interaction of two physical elements. We can identify examples of cutting mechanics (processes including high speed cutting) where explicit schemes can be more efficient than implicit schemes These examples define the term of HighSpeed Machining (HSM), which conditions are complex and difficult fulfill by the available machine tools. There is no comparison between explicit and implicit time integration schemes of the numerical modeling of cutting process using the same spatial discretization and numerical method. The main goal of this work is to contribute to the second reason and develop criteria that allow the user of metal cutting simulations to select the most efficient time integration scheme according to their cutting conditions based in the spatial discretization.
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