Modelling of Vibration Assisted Machining using the PFEM

  • Carbonell, Josep Maria (CIMNE / UVic-UCC)
  • Bakhshan, Hadi (CIMNE)
  • Oñate, Eugenio (CIMNE)

Please login to view abstract download link

Vibration assisted machining (VAM) techniques can used to generate improved surfaces in manufactured parts. It is known that inducing vibration during the plastic deformation of metallic type parts modifies they hardening behaviour making them easier to mold. In machining that contributes to the reduction of cutting forces, the generation of finer chips and the improvement of finished parts. It can be used to produce parts with tighter tolerances and a better surface finish. The numerical modelling of VAM must be able to capture the effect of vibration on the constitutive behaviour of the material. Classical Johnson-Cook´s models are modified to account for this phenomenon. Complex thermomechanical interactions are present: contact between cutting tools and parts, thermal transfer effects, large deformations and distortions of the material and cutting. Characterizing of all these processes and interactions is challenging. In this work we use the Particle Finite Element Method (PFEM) for the numerical modelling of the VAM processes. The characterization of the finished surface, the residual stresses that remain in the processed material and the prediction of the tool lifespan, are some of the objectives. The virtues of the method and application examples will be presented.