Application of Three Dimensional Finite Element Modeling for the Simulation of Machining Processes

摘要

For many years,metal cutting simulations have been performed using two dimensional approximations of the actual process.Factors such as chip morphology,cutting force,temperature,and tool wear can all be predicted on the computer.However,two dimensional simulation is limited to processes which are orthogonal,or which can be closely approximated as orthogonal.Advances in finite element technology,coupled with continuing improvement in the availability of low cost,high performance computer hardware,have made the three dimensional simulation of a large variety of metal cutting processes practical.Specific improvements include efficient FEM solvers,and robust adaptive remeshing.As researchers continue to gain an improved understanding of wear,material representation,tool coalings,fracture,and other such phenomena,the machining simulation system also must adapt to incorporate these evolving models.To demonstrate the capabilities of the 3D simulation system,a variety of drilling,milling,and turning processes have been simulated and will be presented in this paper.Issues related to computation time and simulation accuracy will also be addressed.