An Improved Particle Finite Element Method for the Simulation of Machining Processes

Machining is one of the most common and versatile manufacturing processes in industry, e.g. automotive industry and aerospace industry. But classical numerical methods such as the Finite Element Method (FEM) have difficulties to simulate it, because the material undergoes large deformations, large strain, large strain rates and high temperatures in this process. One option to simulate such kind of problems is the Particle Finite Element Method (PFEM) which combines the advantages of continuum mechanics and discrete modeling techniques. In this study we develop the PFEM further and call it the Adaptive Particle Finite Element Method (A-PFEM). Compared to the PFEM the A-PFEM enables insertion of particles and improves significantly the mesh quality along the numerical simulation. The A-PFEM improves accuracy and precision, while it decreases computing time and resolves the phenomena that take place in machining. Because metal cutting involves plastic deformation we resort to the J? flow theory with isotropic hardening. At last some numerical examples are presented to compare the performance of the PFEM and A-PFEM