My problem is to develop a simulation model and determine the temperature distribution in the cutting zone. I'm doing this in explicit dynamic. Can anyone help me in finding the best way to find temperature distribution and cutting force during machining or how to add user defined output.

# Explicit dynamic modeling of machining process coupled with thermal

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Subhash, I did a simple illustration for a test model of Aluminium block as shown a while back.

So, the crucial part is that you would need to have element erosion criteria defined.

Regards,

Sandeep

Sir, Thank you for your response it was very helpful.

Another doubt was in case of explicit dynamics there are no direct option to find temperature generation in the cutting zone and also to find cutting forces so can you please help me out with this.

And also can u share the type of contact you have used in that model.

Subhash,

You would have to insert temperature through the worksheet:

and for the contact forces, you should make sure that this is turned on in Analysis settings:

I used simple frictionless body interaction, which had self-contact turned on:

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Regards,

Sandeep

Thank you so much sir I got it.

How to solve the same problem using Arbitrary Lagrangian-Eulerian formulation. Is there any way to specify this formulation.

Subhash,

First, you would need to add the material(Say 'Water' for example) as needed in the Engineering Data. Next, in the details of the geometry assignment for the body, you need to specify the Eulerian reference:

Then you would have to make changes to the Analysis settings as needed:

Regards,

Sandeep

Sir, I tried this one but this will become eulerian formulation right?

Subhash,

You are only specifying the Eulerian formulation for the bodies of interest (that would deform significantly) and by changing the scope to Eulerian Bodies alone in the Analysis setting, you are separating this from the Lagrangian aspect. So for the Other/Remaining bodies, the Reference Frame will still be Lagrangian.

Regards,

Sandeep

Ok sir thank you.

What kind of meshing will best suit these kind of problems.

Sir can I know the boundary conditions you have used.

I would recommend using linear Hex elements when every possible in Explicit problems.

The boundary conditions are shown in the first picture of the first post of this thread.

Ok sir. I'm getting an error like energy error too large . What might be the cause of it How can I solve it.

Dear Sirs,

For brittle workpiece material like grey cast iron, is there any way to model the chip formation without setting geometric strain limit on?

By the way what exactly geometric strain limit controls, equivalent elastric strain?

I would like to model chip formation when the workpiece material reaches maximum shear stress or I want to set a limit to plastic strain, I dont expect any plastic strain at all.

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