3D finite element micro drilling simulation multiphase materials

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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.