3D FE micro drilling simulation of multiphase materials


The mechanics of the cutting process on the microscopic level differ fundamentally from the conventional macro cutting. For example, the tool edge radius influences the cutting mechanism in micro machining significantly with regard to the effective rake angle, the minimum chip thickness, the dominance of ploughing, and the related elasto-plastic deformation of the workpiece material. These phenomena, known as size effects, have a profound impact on the cutting forces, process stability, and resulting surface finish in micro cutting. Therefore, the simulation of microstructural effects from micro cutting requires new modeling approaches and quite different assumptions concerning the thermo-mechanical material behavior. Against this background, a 3D multiphase FE computational model is developed at WZL within the framework of the DFG project “3D Finite Element Micro drilling Simulation of multiphase materials” and successfully validated for micro cutting ferritic-pearlitic carbon steels (cf. figure 1).

Main topics:

  • Experimental determination and modelling of size and scaling effects
  • More precise FE computation of cutting force, temperature and the minimum undeformed chip thickness
  • Increase of the process reliability and the quality of micro tools
  • Optimisation of the process performance and the component accuracy.

The research works are supported by:


Do you have questions concerning this project?

Your contact:
Dr.-Ing. Mustapha Abouridouane
Cluster Produktionstechnik 3A 242
Tel.: +49 241 80-28176
Fax: +49 241 80-22293
Mail: M.Abouridouane@wzl.rwth-aachen.de


Markus Meurer, M.Sc. RWTH
Workgroup Leader
Cluster Produktionstechnik 3A 254
Tel.: +49 241 80-28040
Fax: +49 241 80-22293
Mail: M.Meurer@wzl.rwth-aachen.de