Simulation of cutting processes using mesh-free Lagrangian particle methods

Abstract

This contribution presents the model of a `granular solid' based on the Discrete Element Method which is used to model cutting processes of cohesive and ductile materials, e.g. aluminum. The model is based on a conventional three-dimensional Discrete Element approach which employs rigid spheres as it is used to model granular media. Including cohesive interactions besides the repulsive interactions of the basic model allows for the particle agglomerate to display cohesive and ductile behavior. Using the thus generated granular solid the failure modes of ductile engineering materials like aluminum can be qualitatively and quantitatively reproduced. This is shown by comparison with experiments of a tensile and a Charpy impact test. To show the applicability of the approach for manufacturing problems an orthogonal cutting process of steel and aluminum is modelled and the cutting forces are compared to experiments. To further enhance the model thermal interactions between particles are included. The thermodynamics during cutting due to dissipative phenomena is evaluated and compared to experiments.