Hi, I am working on Abaqus/Explicit for chip morphology in 2D orthogonal metal cutting (turning) of Ti6Al4V with WC tool. Upto my knowledge, I followed correct procedure for simulation. After submitting the job almost after 3,00,000 iterations, it is aborting with following error "The elements contained in element set ErrElemExcessDistortion-Step1 have distorted excessively.". I used adaptive meshing for chip portion in work piece. I even ran simulation by reducing frequency and increasing "Remeshing sweeps per increments", still same error is coming. I feel, chip is not coming out from the material. I used CPE4R element type meshing. I am attaching my simulation file and frame images here. After 8th frame, it is aborting. All the material properties and constants are realistic. Please have a look and help me in this regard.
If you want to model machining, you need to define a failure criterion (like shear failure) for the elements so that material can actually separate.
@ Martin Baeker- Thanks for your reply.
I am using J-C fracture model and material constants are according to Guang Chen et. al, (2011) i.e. d1= -0.09, d2=0.25, d3=-0.5, d4= 0.014, d5= 3.87 for Ti-alloy.....
Article Finite element simulation of high-speed machining of titaniu...
@Farbod, Thanks for your information. Status was on during my simulation. I also defined damage evaluation factor as 0.01. I want to know, how exactly this displacement at fracture affects our chip formation.
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