Abaqus Training Seminar

for Machining Simulation

Mohamed Elkhateeb
Date: Sept. 29. 2017

PURDUE – CLAM
http://engineering.purdue.edu/CLM/

Purdue University : Center for Laser-based Manufacturing PURDUE – CLAM

Content
1. Machining simulation Methodology
2. Abaqus Workbench
3. 2D Machining Simulation of AISI 4140
Steel
4. 3D Machining Simulation of Ti6Al4V
Interaction
5. Conclusion
6. ALE

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1. Machining simulation Methodology

FEM

Boundary Running
Geometry Material Type Interaction Meshing
Conditions Simulation

2D Properties Dynamic Property Type Tool Results

Dynamic -
3D Constitutive Type Size Workpiece
Temp

“Simulation is invaluable until it agrees with experimental results”, Prof. Yung Shin.

Purdue University : Center for Laser-based Manufacturing PURDUE – CLAM

2. Abaqus Workbench

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 3. 2D Machining Simulation of AISI 4140 Steel [1]

o Orthogonal Cutting of AISI 4140.

o Workpiece
 Material: AISI 4140 Steel
 Dimensions: 2mm x 0.6mm
o Cutting Tool
 Uncoated Tungsten Carbide
 Dimensions (selective): 0.2mm x 0.8mm
 Angles: neutral rake angle – 7o clearance angle
o Cutting Conditions
 Feed: 0.1mm/rev , Depth of cut (width): 2.5mm, and Cutting speed: 100m/min

Cutting direction Cutting tool

Feed: 0.1mm

Workpiece

1. Akbar F, Mativenga PT, Sheikh M. An experimental and coupled thermo-mechanical finite element study of heat partition effects in
machining. The International Journal of Advanced Manufacturing Technology. 2010;46(5-8):

Purdue University : Center for Laser-based Manufacturing PURDUE – CLAM

 3.1 Geometry Creation
o Creating the geometry of the tool and workpiece through the part module.
o Create each individually and then assemble them (dependent and independent assembly) in the
assembly module..
Sketch basic entities
Create the part

3D features

Units consistency
Partitioning

References

Sketch Dimensions
& Units

Reference point (rigid body)

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3.2 Material
Create a material

Create a section
Assign section
to partition

Depth of cut

Workpiece

o Based on analysis requirements: thermal - dynamic

o Cutting Tool: elastic and thermal properties
o Workpiece: elastic, plastic, damage, and thermal
properties.
o Partition the workpiece: damage layer (larger than
edge radius) – more stable.
o The depth of cut is used as the plane stress/strain
thickness.

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3.2 Material
o Constitutive model
 Used to describe the material deformation behavior.
 Obtained by fitting stress strain curves to certain models, e.g. Johnson cook model.

o Damage Criteria
 Describe chip separation.
 Damage initiation: start of degradation in stiffness

 Damage evolution and element deletion.

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3.3 Meshing the parts Seed Edge
Seed the part
o Area of interest; dense mesh
o Other areas; coarse mesh
o Mesh Sensitivity
 Underfitting Mesh the part
 Overfitting
 Fitting
 Computational cost Mesh region
o Element type:
 Coupled Temperature displacement
 Plain strain: homogeneous – constant
deformation in the third direction Select Element type
 Plain stress: heterogeneous – different
Poisson’s ratio – different deformation
in the third direction
o Element deletion: damage layer

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 3.4 Assembly
Import parts - instances
(repeatable)

Operations on parts

Partitioning (Dependent)

References

Dependence on parts

Offset overlapping parts

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3.5 Analysis Type
o Dynamic – Explicit
 Integrate the equations of motion through time.

 Using the lumped mass matrix M, the nodal accelerations easily at any given time, t, can
be calculated by:

where P is the external load vector and I is the internal load vector.
 Results: cutting forces, stresses, strains, displacement.
o Dynamic, Temp-Disp, explicit

where CNJ is the lumped capacitance matrix, PJ is the applied nodal source vector,
and FJ is the internal flux vector.
 Computationally expensive.

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3.5 Analysis Type Analysis
o Determine analysis type:
 Dynamic: no thermal analysis
 Dynamics
o Define simulation time
o Mass scaling: simulation time
reduction
o Output failure: status
o Number of output intervals.

Output variable

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3.5.1 Arbitrary Lagrangian-Eulerian (ALE)
o ALE combines the features of pure Lagrangian analysis and
pure Eulerian analysis.
 Mesh motion is constrained to the material motion only where
necessary (at free boundaries)
 Otherwise, material motion and mesh motion are independent.
o ALE was applied only on chip area.
o To apply ALE, it is required to define:
 The domain
 Frequency
 No. of sweeps
 Smoothing parameters:
 Volume
 Laplacian
 Equipotential

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3.6 Interaction
Interaction
Property
o Define how tool is interacting with the
workpiece.
Constraint
o The tool is defined as rigid body:
constraint - geometry and reference
point.
o Define interaction properties: tangential
(friction) , normal, heat generation,
thermal conductance (computational
cost)
o Interaction with the workpiece: surface
to node area.

Tool surface -
workpiece node
interaction

Rigid body constraint

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3.7 Boundary conditions
o B.Cs include: fixing the bottom and left surfaces of the workpieces, applying cutting speed to the tool in the
cutting direction and fixing motion in others.
o Define initial status then modify status of the tool at the step of analysis.
o Define initial temperature.

Tool

Workpiece
Initial
Temperature

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 3.8 Running simulation (Job) and results
Create a Job Submit

Parallelization

Single – double
precision

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3.9 Plotting results (Cutting forces)

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3.10 Results

700
650
625 Fc Exp. Fc Sim.
600
Ff Exp. Ff Sim.
Cutting Force (N)

500

400

300

200
Von-Mises Stress Distribution
100 75 70

0
100m/min
Cutting speed (m/min)

Simulation cutting forces compared to experimental results [1]

Temperature Distribution
1. Akbar F, Mativenga PT, Sheikh M. An experimental and coupled thermo-mechanical finite element study of heat partition effects in
machining. The International Journal of Advanced Manufacturing Technology. 2010;46(5-8):

Purdue University : Center for Laser-based Manufacturing PURDUE – CLAM

4. 3D Machining Simulation of Ti6Al4V [2]
o Longitudinal Turning of Ti6Al4V.
o Workpiece
 Material: Ti6Al4V
 Dimensions: 25.4 in diameter
o Cutting Tool
 Uncoated Tungsten Carbide
 Dimensions : 0.012mm edge radius – 0.8mm nose radius
 Angles: 5o angle – 5o clearance angle
o Cutting Conditions
 Feed: 0.076mm/rev , Depth of cut (width): 0.76mm, and Cutting speed: 107m/min

2. Dandekar, C. and Shin, Y.C., “Machinability Improvement of Ti6Al4V Alloy via LAM and
Hybrid Machining”, International Journal of Machine Tools and Manufacture, Volume 50, Issue 2, pp. 174-182, February
2010.

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4.1 Geometry, Materials, Meshing, and Assembly
o 3D – Nose Turning
 Mimics the actual machining process including the effect of nose radius.

Workpiece Cutting Tool Mesh and Assembly

o Johnson-cook constitutive models were used to describe the deformation and damage behaviors of Ti6Al4V [2].
o Only elastic and thermal properties were used for Tungsten carbide [2].
o 3D stress elements are used in meshing.
A B Melting Reference
J-C constitutive model C n m
(MPa) (MPa) Temperature (oC) Temperature (oC)
862 331 0.012 0.34 0.8 1660 20

D1 D2 D3 D4 D5
J-C damage model
-0.09 0.25 -0.5 0.014 3.87

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4.2 Analysis, Interaction, and B.Cs
o Dynamic, Temp-Disp, Explicit analysis was used
o Property: contact, describe the behavior of interaction
 Normal
 Tangential - friction
• Coulomb’s friction law
 Thermal conductance
 Heat Generation
o Interaction -Type
 General
 Applies only for 3D
 Surface: Master Slave
 Surface –surface
 Surface - node
o Constraint
 Rigid body: tool – reference point
o Tool
 Move only in the cutting direction with the cutting Speed
– Reference Point.
 Initial temperature.
o Workpiece
 Fully constrained surfaces (bottom and side surfaces)
 Initial Temperature

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4.3 Results

160 150 152 Fc Exp. Fc Sim.

140
Ft Exp. Ft Sim.
118
Cutting Force (N)

120 111
100
100 93
80
60 50
43 40 36 37 35
40
20
0
25 250 500
Workpiece Temperature (oC)

Simulation cutting forces compared to experimental results [2]

2. Dandekar, C. and Shin, Y.C., “Machinability Improvement of Ti6Al4V Alloy via LAM and Hybrid Machining”, International Journal of Machine
Tools and Manufacture, Volume 50, Issue 2, pp. 174-182, February 2010.

Purdue University : Center for Laser-based Manufacturing PURDUE – CLAM

5. Conclusion
o Finite element simulation of orthogonal and
longitudinal turning was discussed.
o They include: geometry creation, material definition,
meshing, assembly, selecting analysis ,methodology,
defining interaction, running simulation, and
visualizing results.
o Constitutive models for workpiece material are
required to describe material behavior during
simulation.
o Two case studies were presented and results showed
agreement with experimental results.

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