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

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.