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Dynamic simulation of machining composites using the explicit element-free Galerkin method

机译：使用显式无元素Galerkin方法进行复合材料加工的动态模拟

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摘要

Machining operations are performed on composite parts to obtain the final geometry. However, machining composites is challenging due to their low machinability and high cost. Numerical modelling of machining presents a valuable tool for cost reduction and a better understanding of the cutting process. Meshfree methods are an attractive choice to model machining problems due to their capability in modelling large deformations. This work presents an explicit meshfree model for orthogonal cutting of unidirectional composites based on the element-free Galerkin (EFG) Method. Advantages of the proposed model include: simple and automated preprocessing, advanced material modelling and ability to model high-speed machining. Workpiece material is modelled as orthotropic Kirchhoff material with a choice of three failure criteria: maximum stress, Hashin and LaRCO2. Frictional contact calculations are performed based on central differencing, therefore avoiding the use of penalty parameters. Validation of the EFG model is conducted by comparing cutting forces against orthogonal cutting experiments on GFRP samples using a vertical milling machine. It is found that while the numerical cutting forces are in good agreement with experimental ones, the numerical thrust forces are significantly underestimated. Analysis of failure showed that chip is formed along the fibre direction in the studied range.
机译：对复合零件执行机加工操作以获得最终几何形状。然而，由于其可加工性低且成本高，因此加工复合材料具有挑战性。机加工的数值建模为降低成本和更好地了解切削过程提供了一种有价值的工具。由于无网格方法具有对大型变形进行建模的功能，因此它们是对加工问题进行建模的诱人选择。这项工作提出了一种基于无元素Galerkin（EFG）方法的用于单向复合材料正交切削的显式无网格模型。该模型的优点包括：简单且自动化的预处理，先进的材料建模以及对高速加工进行建模的能力。工件材料建模为正交各向异性基尔霍夫材料，可以选择三个破坏准则：最大应力，Hashin和LaRCO2。摩擦接触计算是基于中心差执行的，因此避免了使用惩罚参数。 EFG模型的验证是通过使用立式铣床对GFRP样品的切削力与正交切削实验进行比较来进行的。发现虽然数值切削力与实验数值吻合良好，但数值推力却被大大低估了。失效分析表明，在研究范围内沿纤维方向形成了切屑。

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