What is a separation layer or sacrifice layer in Abaqus in simulation of metal cutting. How to create it. What are the boundary conditions/constraints we give?
During my metal cutting simulation, I am facing error like elements are highly distorted. Does creating a sacrifice layer help for me?
It is used to allow separation of material at the tool tip - elements are deleted there. You create it using some failure criterion. There is a very large number of papers on the subject that explains this in detail.
You need such layer in order to simulate the process of chip generation. However, physically, it doesn't exist. This layer is created in between the chip & workpiece, and when it fails (after satisfying a pre-defined failure criterion) the chip is generated. Hope this helps.
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