Efficient Modelling of Chip Formation in Orthogonal Cutting Based on Isogeometric Analysis and Modern Methods for Material Characterization

基于等几何分析和现代材料表征方法的正交切削中切屑形成的高效建模

• 批准号: 405652718
• 负责人: Professorin Dr.-Ing. Stefanie Elgeti
• 金额: --
• 依托单位: Institut für Leichtbau und Struktur-Biomechanik
• 依托单位国家: 德国
• 项目类别: Research Grants
• 财政年份: 2018
• 资助国家: 德国
• 起止时间: 2017-12-31 至 2020-12-31
• 项目状态: 已结题
• 来源: https://gepris.dfg.de/gepris/projekt/405652718?language=en
• 关键词: Efficient; Modelling; Chip; Formation; Orthogonal

The proposed project considers the numerical simulation of chip formation and its potential to estimate process parameters for cutting processes. Also available in commercial software, the numerical simulation of chip formation based on the finite element method is a commonly used approach to predict the complex thermo-mechanical effects in cutting; in particular in the vicinity of the cutting edge. However, the state of the art shows limitations, i.e. on the one hand the actual chip formation simulations permit only the representation of very short process sequences and on the other hand their underlying models are of limited validity; in particular in terms of the quantitatively prediction of process values such as forces, stresses, strains, temperatures, and chip shapes. These limitations are partially due to insufficient material and friction models, however, there exists clear evidence that the utilized finite element meshes (refinement, element type, element deformation and orientation) have a strong influence not only on the accuracy of the numerical result, but also on the general phenomena that can be captured. This includes in especially the development of shear bands. These dependencies are intended to be resolved via the use of modern numerical methods, namely isogeometric analysis (IGA) and space-time finite elements.The specific scientific aim of the proposed project is to develop a modern numerical analysis tool for chip formation based on isogeometric analysis and the in computational fluid dynamics already established Deforming-Spatial-Domain/Stabilized Space-Time (DSD/SST) method. The new tool is to be assessed in terms of efficiency and accuracy, in particular regarding effects in the primary and secondary shear zone, but also the workpiece surface zone. It has to be supported by modern methods of material characterization. On the methodological side, an understanding of the behavior IGA presents when modeling dynamic contact problems with thermodynamically coupled material equations. Especially the significant reduction of numerical errors, which are induced through remeshing steps, are expected to lead to an increase in numerical accuracy. This constitutes an important step for chip formation simulation and will immediately improve its applicability.

提出的项目考虑了芯片形成的数值模拟及其对切割过程的过程参数的潜力。同样在商业软件中也可以使用，基于有限元方法的芯片形成的数值模拟是一种常用的方法，可预测切割中复杂的热机械效应。特别是在尖端的附近。但是，最新的状态显示出局限性，即一方面，实际的芯片形成模拟仅允许表示非常短的过程序列的表示，另一方面，它们的基本模型的有效性有限；特别是关于工艺值的定量预测，例如力，应力，应变，温度和芯片形状。这些局限性部分是由于材料和摩擦模型不足，但是存在明确的证据表明，使用的有限元网格（细化，元素类型，元素变形和方向）不仅对数值结果的准确性，而且对可以捕获的一般现象的影响都有很大的影响。这尤其包括剪切带的发展。 These dependencies are intended to be resolved via the use of modern numerical methods, namely isogeometric analysis (IGA) and space-time finite elements.The specific scientific aim of the proposed project is to develop a modern numerical analysis tool for chip formation based on isogeometric analysis and the in computational fluid dynamics already established Deforming-Spatial-Domain/Stabilized Space-Time (DSD/SST) method.新工具应根据效率和准确性进行评估，尤其是在初级和次要剪切区的效果方面，以及工件表面区域的影响。它必须由现代物质表征的方法来支持。在方法论方面，对行为IgA的理解在对热力学耦合材料方程进行建模时会出现。尤其是通过重组步骤引起的数值误差的显着降低，预计将导致数值准确性的提高。这构成了芯片形成模拟的重要步骤，并将立即提高其适用性。