Numerical Methods for the Modelling of Chip Formation

The modeling of metal cutting has proved to be particularly complex due to the diversity of physical phenomena involved, including thermo-mechanical coupling, contact/friction and material failure. During the last few decades, there has been significant progress in the development of numerical methods for modeling machining operations. Furthermore, the most relevant techniques have been implemented in the relevant commercial codes creating tools for the engineers working in the design of processes and cutting devices. This paper presents a review on the numerical modeling methods and techniques used for the simulation of machining processes. The main purpose is to identify the strengths and weaknesses of each method and strategy developed up-to-now. Moreover the review covers the classical Finite Element Method covering mesh-less methods, particle-based methods and different possibilities of Eulerian and Lagrangian approaches

The Double Hierarchy Method: a parallel 3D contact method for the interaction of spherical particles with rigid FE boundaries using the DEM

The final publication is available at Springer via http://dx.doi.org/10.1007/s40571-016-0109-4In this work, we present a new methodology for the treatment of the contact interaction between rigid boundaries and spherical discrete elements (DE). Rigid body parts are present in most of large-scale simulations. The surfaces of the rigid parts are commonly meshed with a finite element-like (FE) discretization. The contact detection and calculation between those DE and the discretized boundaries is not straightforward and has been addressed by different approaches. The algorithm presented in this paper considers the contact of the DEs with the geometric primitives of a FE mesh, i.e. facet, edge or vertex. To do so, the original hierarchical method presented by Horner et al. (J Eng Mech 127(10):1027–1032, 2001) is extended with a new insight leading to a robust, fast and accurate 3D contact algorithm which is fully parallelizable. The implementation of the method has been developed in order to deal ideally with triangles and quadrilaterals. If the boundaries are discretized with another type of geometries, the method can be easily extended to higher order planar convex polyhedra. A detailed description of the procedure followed to treat a wide range of cases is presented. The description of the developed algorithm and its validation is verified with several practical examples. The parallelization capabilities and the obtained performance are presented with the study of an industrial application example.Peer ReviewedPostprint (author's final draft

Lagrangian formulation for finite element analysis of quasi-incompressible fluids with reduced mass losses

We present a Lagrangian formulation for finite element analysis of quasi-incompressible fluids that has excellent mass preservation features. The success of the formulation lays on a new residual-based stabilized expression of the mass balance equation obtained using the Finite Calculus (FIC) method. The governing equations are discretized with the FEM using simplicial elements with equal linear interpolation for the velocities and the pressure. The merits of the formulation in terms of reduced mass loss and overall accuracy are verified in the solution of 2D and 3D quasi-incompressible free-surface flow problems using the Particle Finite Element Method (PFEM, www.cimne.com/pfem). Examples include the sloshing of water in a tank, the collapse of one and two water columns in rectangular and prismatic tanks and the falling of a water sphere into a cylindrical tank containing water. Copyright c 0000 John Wiley & Sons, Ltd

Unified Lagrangian formulation for solid and fluid mechanics and FSI problems

We present a Lagrangian monolithic strategy for solving fluid-structure interaction (FSI) problems. The formulation is called Unified because fluids and solids are solved using the same solution scheme and unknown variables. The method is based on a mixed velocity-pressure formulation. Each time step increment is solved via an iterative partitioned two-step procedure. The Particle Finite Element Method (PFEM) is used for solving the fluid parts of the domain, while for the solid ones the Finite Element Method (FEM) is employed. Both velocity and pressure fields are interpolated using linear shape functions. For quasiincompressible materials, the solution scheme is stabilized via the Finite Calculus (FIC) method. The stabilized elements for quasi-incompressible hypoelastic solids and Newtonian fluids are called VPS/S-element and VPS/F-element, respectively. Other two non-stabilized elements are derived for hypoelastic solids. One is based on a Velocity formulation (V-element) and the other on a mixed Velocity-Pressure scheme (VP-element). The algorithms for coupling the solid elements with the VPS/F fluid element are explained in detail. The Unified formulation is validated by solving benchmark FSI problems and by comparing the numerical solution to the ones published in the literature

Performance of mixed formulations for the particle finite element method in soil mechanics problems

This paper presents a computational framework for the numerical analysis of fluid-saturated porous media at large strains. The proposal relies, on one hand, on the particle finite element method (PFEM), known for its capability to tackle large deformations and rapid changing boundaries, and, on the other hand, on constitutive descriptions well established in current geotechnical analyses (Darcy’s law; Modified Cam Clay; Houlsby hyperelasticity). An important feature of this kind of problem is that incompressibility may arise either from undrained conditions or as a consequence of material behaviour; incompressibility may lead to volumetric locking of the low-order elements that are typically used in PFEM. In this work, two different three-field mixed formulations for the coupled hydromechanical problem are presented, in which either the effective pressure or the Jacobian are considered as nodal variables, in addition to the solid skeleton displacement and water pressure. Additionally, several mixed formulations are described for the simplified single-phase problem due to its formal similitude to the poromechanical case and its relevance in geotechnics, since it may approximate the saturated soil behaviour under undrained conditions. In order to use equal-order interpolants in displacements and scalar fields, stabilization techniques are used in the mass conservation equation of the biphasic medium and in the rest of scalar equations. Finally, all mixed formulations are assessed in some benchmark problems and their performances are compared. It is found that mixed formulations that have the Jacobian as a nodal variable perform better

Continuous chip formation in metal cutting processes using the Particle Finite Element Method (PFEM)

This paper presents a study on the metal cutting simulation with a particular numerical technique, the Particle Finite Element Method (PFEM) with a new modified time integration algorithm and incorporating a contact algorithm capability . The goal is to reproduce the formation of continuous chip in orthogonal machining. The paper tells how metal cutting processes can be modelled with the PFEM and which new tools have been developed to provide the proper capabilities for a successful modelling. The developed method allows for the treatment of large deformations and heat conduction, workpiece-tool contact including friction effects as well as the full thermo-mechanical coupling for contact. The difficulties associated with the distortion of the mesh in areas with high deformation are solved introducing new improvements in the continuous Delaunay triangulation of the particles. The employment of adaptative insertion and removal of particles at every new updated configuration improves the mesh quality allowing for resolution of finer-scale features of the solution. The performance of the method is studied with a set of different two-dimensional tests of orthogonal machining. The examples consider, from the most simple case to the most complex case, different assumptions for the cutting conditions and different material properties. The results have been compared with experimental tests showing a good competitiveness of the PFEM in comparison with other available simulation tools

The particle finite element method (PFEM) in thermo‐mechanical problems

The aim of this work is to develop a numerical framework for accurately and robustly simulating the different conditions exhibited by thermo‐mechanical problems. In particular, the work will focus on the analysis of problems involving large strains, rotations, multiple contacts, large boundary surface changes, and thermal effects. The framework of the numerical scheme is based on the particle finite element method (PFEM) in which the spatial domain is continuously redefined by a distinct nodal reconnection, generated by a Delaunay triangulation. In contrast to classical PFEM calculations, in which the free boundary is obtained by a geometrical procedure (α − shape method), in this work, the boundary is considered as a material surface, and the boundary nodes are removed or inserted by means of an error function. The description of the thermo‐mechanical constitutive model is based on the concepts of large strains plasticity. The plastic flow condition is assumed nearly incompressible, so a u‐p mixed formulation, with a stabilization of the pressure term via the polynomial pressure projection, is proposed. One of the novelties of this work is the use of a combination between the isothermal split and the so‐called IMPL‐EX hybrid integration technique to enhance the robustness and reduce the typical iteration number of the fully implicit Newton–Raphson solution algorithm. The new set of numerical tools implemented in the PFEM algorithm, including new discretization techniques, the use of a projection of the variables between meshes, and the insertion and removal of points allows us to eliminate the negative Jacobians present during large deformation problems, which is one of the drawbacks in the simulation of coupled thermo‐mechanical problems. Finally, two sets of numerical results in 2D are stated. In the first one, the behavior of the proposed locking‐free element type and different time integration schemes for thermo‐mechanical problems is analyzed. The potential of the method for modeling more complex coupled problems as metal cutting and metal forming processes is explored in the last example

Damage analysis of masonry structures subjected to rockfalls

Masonry structures present substantial vulnerability to rockfalls. The methodologies for the damage quantification of masonry structures subjected to rockfalls are scarce. An analytical procedure for the damage assessment of masonry structures is presented. The procedure comprises three stages: (1) determination of the rockfall impact actions which are applied to a masonry structure, in terms of external forces, using the particle finite element method (PFEM), (2) evaluation of the mechanical properties, modelling of the masonry structure, and calculation of the internal stresses, using the finite element method (FEM), (3) assessment of the damage due to the rockfall actions, applying a failure criterion adapted to masonries, and calculation of the damage in terms of the percentage of the damaged wall surface. Three real rockfall events and their impact on buildings are analysed. A sensitivity analysis of the proposed procedure is then used to identify the variables that mostly affect the extent of the wall damage, which are the masonry width, the tensile strength, the block diameter and lastly, velocity

Numerical methods for the modelling of chip formation

The modeling of metal cutting has proved to be particularly complex due to the diversity of physical phenomena involved, including thermo-mechanical coupling, contact/friction and material failure. During the last few decades, there has been significant progress in the development of numerical methods for modeling machining operations. Furthermore, the most relevant techniques have been implemented in the the relevant commercial codes creating tools for the engineers working in the design of processes and cutting devices. This paper presents a review on the numerical modeling methods and techniques used for the simulation of machining processes. The main purpose is to identify the strengths and weaknesses of each method and strategy developed up-to-now. Moreover the review covers the classical Finite Element Method covering mesh-less methods, particle-based methods and different possibilities of Eulerian and Lagrangian approaches.Postprint (author's final draft