I'm working on simulating turning process of AISI 1045 steel to get stress and temperature distributions. First i submitted a simulation job with step time of 0.005 sec and it completed successfully after 16 hours. My work piece rotational speed was 1000 rad/sec and the cutting tool feed rate was 2.75 m/sec. Now i'm trying to increase my step time to 0.5 second and decrease rotational speed to 200 rad/sec and the feed rate to 0.01375 m/sec which are more realistic values. However, when i submit the new job, i face this error: "The analysis may need a large number of increments (more than 20,000,000) and it may be affected by round off errors. for accuracy, running double precision executable is required". I only changed step time, rotational speed and feed rate. Please help me with this error. how can i fix that?
I have also attached a number images from my results. You might want to take a look at them.
Try using Solver Controls; relaxing the tolerances may help in convergence.
Sumeru Nayak could you please explain more? what exactly do i need to do?
in abaqus, others—> solver controls —> manager; you can try increasing the tolerances. it often works for problems with convergence issues.
Saeed Behzadi Need your help in simulating chips (any hint for correction). For full cylinder workpiece, they disappear just after forming.
Chips form only when the tool is placed at final position before machining (attached picture).
Try different element sizes and aspect ratios for workpiece. otherwise, change the feed rate at least for the beginning of motion until a little while after contact. to my experience, it is solved by try and error.
Increasing step time does not always reduce simulation time. This can even cause convergence problems
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