TECHNOLOGIES

Finite Element Method (FEM) Model Development for Cutting Process Simulation Using Mentat and Marc Solver

  • 1 Slovak University of Technology in Bratislava, Faculty of Material Science and Technology in Trnava, Slovakia

Abstract

This study presents the development of a Finite Element Method (FEM) model to simulate cutting processes, focusing on the analysis of various parameters such as stress, strain, temperature, and cutting forces in the cutting zone. The FEM model is developed using Mentat software and solved with the Marc solver. By employing this method, we can effectively manage cutting parameters, optimize cutting tool geometry, predict tool wear, and improve tool life. The research investigates key parameters and their values, providing insights into the cutting process that can enhance efficiency and performance. The application of FEM in this context offers a robust framework for advancing the understanding and development of cutting technologies. Various software applications that support these investigations are also explored, underscoring the versatility and precision of FEM in cutting process simulations.

Keywords

References

  1. E. Usui, T. Shirakashi, and T. Kitagawa. Analytical prediction of cutting tool wear. Wear, 100(1-3):129–151, (dec 1984)
  2. F. Matos, T.E.F. Silva, F. Marques, D. Figueiredo, P.A.R. Rosa, and A.M.P. de Jesus. Machinability assessment of inconel 718 turning using PCBN cutting tools. Procedia CIRP, 117:468– 473, (2023)
  3. Jay Airao and Chandrakant K. Nirala. Finite element modeling and experimental validation of tool wear in hot-ultrasonic-assisted turning of nimonic 90. Journal of Vibration Engineering and Technologies, (nov 2022)
  4. Radu Pavel and A. Srivastava. Thermo-mechanical modeling of metal cut-ting using marc mentat. Transactions of the North American Manufactur-ing Research Institute of SME, 33:581–588, 01 (2005)
  5. Nanyuan Zhang, Hagen Klippel, Mohamadreza Afrasiabi, Matthias Röthlin, Michal Kuffa, Markus Bambach, and Konrad Wegener. Hybrid SPH-FEM solver for metal cutting simulations on the GPU including thermal contact modeling. CIRP Journal of Manufacturing Science and Technology, 41:311–327, (April 2023)
  6. Pedro J. Arrazola and Tug.rul Özel. Investigations on the effects of friction modeling in finite element simulation of machining. International Journal of Mechanical Sciences, 52(1):31– 42, (January 2010)
  7. Panagiotis Kyratsis, Anastasios Tzotzis, and J. Paulo Davim. Fundamen-tals of 3d finite element modeling in conventional machining. In 3D FEA Simulations in Machining, pages 13–46. Springer International Publishing, (2023)
  8. Tobias Wolf, Michael Fast, Jannis Saelzer, Gabriel Brock, Dirk Biermann, and Stefan Turek. Modeling and validation of a FEM chip formation sim1ulation to expand the numerical work on discontinuous drilling of inconel 718. Procedia CIRP, 117:32–37, (2023)
  9. Mahir AKGÜN and Halil DEMİR. Optimization and finite element modelling of tool wear in milling of inconel 625 superalloy. Politeknik Dergisi, 24(2):391–400, ( jun 2021)
  10. Martin NECPAL. Advancing machining manufacturing: A comprehensive evaluation of finite element method simulation for cutting processes. Mathematical modeling, 8(1):32–36, (2024).

Article full text

Download PDF