Hello everyone, I am doing a simulation of orthogonal metal cutting process using CEL method. To make sure the simulation is better, I found a very good SCI paper for reference, but unfortunately I didn't reproduce the perfect chip simulation in the author's paper, the picture below shows the setup of my simulation and the simulation in the paper. (The parameters of material properties of workpiece, parameters of constitutive model and mesh size are exactly the same as those in the paper.) May I ask why the chips in my simulation are not curled normally and form serrated chips? Are there other settings in the CEL simulation that I am not aware of? Any help would be greatly appreciated!
paper link: Article Numerical investigation of sequential cuts residual stress c...
CEL method may not always accurately capture the chip formation process, especially for materials with complex deformation behavior. Therefore, it may be beneficial to consider other simulation methods, such as the Arbitrary Lagrangian-Eulerian (ALE) method, which can better capture the material deformation and chip formation process. The issue you are facing with the chip formation in your orthogonal metal cutting simulation using the CEL method may be due to various factors, including the constitutive model used, the mesh size, and the cutting conditions.
Additionally, the cutting conditions, such as the cutting speed and feed rate, can also affect the chip formation process. It may be helpful to compare the cutting conditions used in the reference paper with those used in your simulation. For more connect with me on Https://wa.me/+923440907874
The problem of chip piling up at tool tip is usually induced by too large strain. Try the following method:
1. Decrease the criterial strain of damage initiation;
2. Decrease the strain hardening exponent n if you're using JC model.
Good luck!
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