COMPLAS 2023

Modelling of wet cutting processes for turning simulations

  • Bock-Marbach, Benjamin (Fraunhofer ITWM)
  • Kuhnert, Joerg (Fraunhofer ITWM)

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In this work we consider a wet cutting process with respect to the forces. While wet cutting is widely applied on industrial turning processes our application is related to chip formation. Large deformations in the cutting process pose severe challenges for mesh-based methods. Additionally, the prediction of cutting forces in wet cutting processes requires a modeling and prediction of a system that represents the 3 participating, interdependent phases: workpiece, tool and cooling lubricant. By using the MESHFREE software we overcome these problems to simulate the interaction of involved liquid and solid phases. MESHFREE solves the differential equations for conservation of mass, momentum and energy of liquid and solid phases, based on the Generalized Finite Difference Method. In the past MESHFREE has been successfully applied in wet cutting processes involving multi-phase fluids/continua. The cutting forces from the workpiece are governed by an inner resistance of the tool, which we model by a Johnson-Cook failure model. Additionally, friction between the workpiece and the tool is considered. The impact of the cooling lubricant plays a minor role on the forces. However, due to the influence of temperature on the yield stresses the cooling lubricant has an important influence. In this contribution we want to present some recent improvements in our model for wet cutting processes.