3D finite element micro drilling simulation multiphase materials

新型复合材料的加工研究和加工工艺向微细范围的扩展，使得开发和验证用于非均质材料有限元模拟的新材料模型成为必要。在此背景下，在DFG项目的框架内，基于代表性体积元(RVE)的概念和本构材料模型，建立了铁素体-珠光体碳钢的两相三维材料模型，并成功地用于C45+N微钻削加工的基于微观组织的综合切割模拟。通过这种基于微观组织的创新建模方法，一方面可以实现对微切削过程反应的逼真预测，另一方面可以更详细地解释微钻削过程中的相互作用机理和尺度效应。拟议继续项目的目标是验证所开发的用于微细铣削和精拉削等附加切割过程的两相有限元切割模型，将其扩展到特别具有挑战性的材料微结构(含有夹杂物和微缺陷的多相组织)，并在减少计算时间和提高稳定性方面进一步发展它。这种多相三维有限元切割模型可以为面向应用的显微组织和加工工艺设计开发新的定制解决方案，从而开辟新的研究领域。

The research on machining of new composite materials and the extending process limits of cutting into the micro range make the development and validation of new material models for the FE cutting simulation heterogeneous materials necessary. Against this background and within the framework of this DFG project, based on the concept of representative volume element (RVE) and constitutive material modelling, a two-phase 3D Material model for ferritic-pearlitic carbon steels was developed and successfully validated for the integrative microstructure-based cutting simulation of micro drilling operations in C45+N. By means of this microstructure-based innovative modelling approach, a realistic prediction of micro cutting process reactions could be achieved on the one hand and interaction mechanisms as well as scaling effects in micro drilling were explained in more details on the other hand. The objective of the proposed continuation project is to validate the developed two-phase FE cutting model for additional cutting processes such as micro milling and finish broaching, to extend it to particularly challenging material microstructures (multiphase microstructure with inclusions and micro defects) and to develop it further with regard to the computation time reduction and stability improvement. New tailor-made solutions for an application-oriented microstructure and machining process design could be developed with this multiphase 3D FE cutting model, whereby new research fields should be opened up.