3D finite element micro drilling simulation multiphase materials

新型复合材料切削加工的研究以及切削加工极限向微观范围的拓展，使得非均质材料有限元切削仿真中新材料模型的开发和验证成为必要。在此背景下，在DFG项目的框架内，基于代表性体积元（RVE）和本构材料建模的概念，开发了铁素体-珠光体碳钢的两相3D材料模型，并成功验证了C45+N中微钻操作的基于微观结构的综合切削模拟。通过这种基于微观结构的创新建模方法，一方面可以实现对微切削过程反应的现实预测，另一方面可以更详细地解释微钻削中的相互作用机制以及缩放效应。拟议的延续项目的目的是验证开发的两相有限元切削模型，用于其他切削工艺，如微铣削和精拉，将其扩展到特别具有挑战性的材料微观结构（含夹杂物和微缺陷的多相微观结构），并在减少计算时间和提高稳定性方面进一步开发。该多相三维有限元切削模型可以为面向应用的微观结构和加工工艺设计提供新的定制解决方案，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.