iMFREE: A versatile software tool for modelling machining processes with particle methods

Abstract

The current state-of-the-art for the simulation of machining process is the application of the FEM (finite element method). Nevertheless, the cost of FEM analyses for such problems is high due to their complex multi-physics nature, mesh regeneration issues, and small time-length scales. In contrast, particle methods are an alternative numerical approach well-suited for large deformations as in material's chip formation. In this work, the key features and simulation capabilities of iMFREE are presented, which is a massively parallel and robust particle-based code for machining simulations developed at the ETH Zürich. Various applications of iMFREE are shown, where the efficiency is demonstrated in orthogonal cutting simulations for the optimisation of material removal rates, a chip formation study, the inverse identifications of friction law parameters and material constitutive law parameters. Further, the applicability to single and multiple grain grinding simulations of Ti6Al4V and silicon is shown.