Hi every one,
I am working on modelling of 2D-orthogonal machining in Abaqus/Explicit. When I am trying with Lagrangian solver (default solver in Abaqus/Explicit), material is subjected to high distortion. I am able to run the simulation but a part of tool is completely penetrated inside the material before element deletes as shown in attached figure. I found from some literature that ALE can help in smoothing the mesh thereby controls the high distortion in the work material.
Thus, I started working on ALE application. However, always it is aborting with error.
Can any one help me in application of ALE in 2D Orthogonal machining,
Kind regards
Prudvi.
Dear Paresi,
You experienced penetration because the difference between the mesh size of the tool and workpiece is too high. You should use smaller elements in the tool compared to element size of workpiece. I also see that the tool radius is not well formed due to coarse mesh. This also lead penetration. I think u should focuse on lagragian analysis.
You may also change the failure criterion for the element near the crack tip so that they fail earlier.
For orthogonal machining, you could also try a completely Eulerian approach (i.e. mesh fixed in space, materia flowing thorugh it), I once had a student doing a thesis on this showing that it works nicely.
As said previously, the mesh should be refined. ALE could help you but I have to admit that coupling damage and ALE did not lead to good results: the elements were deleted as soon as the tool touches the elements.
@Cenk Kılıçaslan, Thank you Cenk. I tried with fine mesh neat tool edge. I can penetration is controlled but still results are much expected. Yes, both ALE and CEL are not giving acceptable results may be due to fracture.
Thank you @François Ducobu, I tried ALE by modelling both WP (applied ALE for WP only) and tool as deformable but it was resulting in high distortion as soon as both come in contact. However when I model tool as analytical rigid and apply ALE for WP, tool was penetrating but as you said elements are deleted immediately and material is flying just like a small air particles. So, I realized ALE for fracture is not recommended.
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