Simulation of machining processes on parts obtained by additive manufacturing

The proposed PhD project is related to the simulation of the machining process of the L-PBF IN718 parts.

Machining processes induce large plastic deformation at high strain rate. Simulation of this process is challenging since on top of the non-linearities related to the high strain rate plastic deformation, it involves the complexities induced by contact and friction between the interface of the material and the tool.

All the numerical simulations will be carried out using the software Forge® which allows handling large deformation and complex contact problems. Forge® is a world-leader Software used for the simulation material forming processes. The current solver available is implicit and is not suitable to study machining processes. The first task of this project involves the development of an explicit solver to simulate the machining process.

The anisotropic constitutive law identified by the other partners of the project will be implemented in Forge® and coupled with the existing damage to fracture modelling framework.

This damage modeling framework is based on the use of the Phase-Field method and intensive remeshing to propagate cracks

Friction conditions will be studied by the partners of the project and will have to be properly introduced in the explicit version of the software.

The coupling between the explicit version of Forge® and the Phase-field damage to fracture framework will allow the simulation of the machining process. The simulation results will be validated with respect to the experimental tests carried out by other project partners.