Hi,
I modeled the 2D cutting of fiber reinforce plastics (composite) materials with ABAQUS. As is shown in the figure, I have problem with excessive element distortion and chip formation. do you have any idea how to solve this problems?
Thank you in advance for any help you can provide.
Modeling parameters:
-Material : composite
-Failure criteria : Hashin (damage stabilization 1e-7 )
-ALE adaptive mesh (frequency 10, sweeps 1)
-interaction (surface to surface contact- penalty contact method)
-step :dynamic explicit
-Mesh type: CPS4R , plane stress
Your deformation pattern looks very weird to me. First of all, cutting should probably be plane strain, not plain stress (CPE4) unless yo are really cutting very thin sheets of material.
Furthermore, to understand what is happening, you might switch of ALE.
Considering the rounded tip of your tool, your mesh is much too coarse to be able to flow around this tool in any sensible way.
Hi,
Firstly, play with ALE parameters and secondly change the mesh pattern. The mesh has to have a special patternin the large deformation region. Look at the 2D extrusion modeling in ABAQUS tutorial.
Regards,
@Ahmed
Problem is that in machning the large deformation region (shear zone) is moving. In my experience, ALE does not help much in machnining, that's why I recommended switching it off.
@Ahmad, @Martin
Thank you so much for your responses. I switched ALE off, but I saw many distortion. Step time period is 0.001 and the scaling factor is 0.01. Should I use lower scaling factor?
I have just 2 frames in my results, is it because of scaling factor ?
Thank you again for your helps.
Do you mean "mass scaling" with scaling factor?
I would switch this off initially, even if the CPU time increases a lot this way.
I mean Step-Edit step- basic -time period (0.001)
Step-Edit step- Incrementation- time scaling factor (0.01)
Why do you set the scaling factor? I would leave this at the default value, unless there is a very compelling reason.
Hi,
I guess:
1. Your problem should be plain strain ( you have a thickness in Z direction)
2.Time scaling? or "mass scaling"? Time scaling should be cheeked based on energies. You can increase it to 0.02 or 0.05 (does not mater s much)
3. Can you show us the meshed part? I seems, still you have not changed the mesh pattern.
4. You are using Hushin's criterion, do you apply the homogenized stiffens properties to you material? Have you defined the local orientation properly? Have you checked your strength properties? This criterion may contradict with "plain strain" assumption! Check it.
5. I am not sure if the Hushin's criterion is enough for damage modeling in cutting process.
Best regards,
Ahmad
Please find the results of my study in the following link (paper)/ or request for the full text:
https://link.springer.com/article/10.1007%2Fs00170-016-8482-y
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