Cutting simulation with the meshfree finite pointset method

Today the Finite Element Method (FEM) is almost exclusively used for the simulation of chip formation. However, this method requires the application of computationally expensive remeshing procedures for a reliable calculation of the material flow through the shear zone. Numerical losses can thereby occur which impedes the analysis of the chip formation mechanisms. Therefore, the Institute for Machine Tools and Manufacturing Technology (IWF) and the Fraunhofer Institute for Industrial Mathematics (ITWM) are currently improving and adapting the Finite Pointset Method (FPM) to allow the meshfree computer modeling of chip formation. Due to the meshfree approach of the FPM, no additional techniques are necessary for the maintenance of a valid mesh structure at large strains. In this work, the different development steps of FPM are described. The accuracy of FPM cutting simulations is evaluated by means of comparisons with results from FEM calculations and machining experiments. The medium carbon steel AISI 1045 and the nickel-based alloy Inconel 718 are used as workpiece materials in the investigations.