Need Help with Chip Formation Issue in 3D Turning Process

[SUMESH C S]

Hello Forum Members,

I am facing an issue with chip formation in a 3D turning process simulation, and I would greatly appreciate any insights or suggestions on how to address this problem. I have attached the .inp file of the model.

Problem Description:
In my 3D turning simulation, I am encountering difficulties with chip formation. The chips are not forming as expected, and this is impacting the accuracy and reliability of my simulation results. Process modelled is Turning operation, Workpiece material: Ti6Al4V alloy, modelled as deformable. Tool material: Tungsten Carbide, modelled as deformable.

Steps Taken So Far:

Checked the tool geometry and cutting parameters to ensure they are set correctly.
Verified the workpiece material properties and machining conditions.
Ran simulations with different cutting speeds, feeds, and depths of cut, but the issue persists.

Request for Assistance:

Has anyone experienced a similar issue with chip formation in a 3D turning simulation?
Are there specific parameters or settings that could be causing this problem?
What strategies or approaches can I try to improve chip formation in the simulation?
Any guidance, tips, or advice would be highly appreciated. Thank you in advance for your help!

Best regards,
SUMESH C S

 

[FEA way]

Can you share this input file as .inp or .txt ? It makes no sense to turn it into a huge .docx document with over 13400 pages. Word struggles to even open it.

 

[SUMESH C S]

Hello members,
Since the inp file size is more than the allowable size, I compressed the file using ,rar application. Can you please check the inp file and tell me the mistakes or corrections needed?
With regards,
SUMESH C S

 

[FEA way]

I can't submit this model, it generates some strange generic errors. Try simplifying it - there are many features (even adaptive meshing - it would be better to refine the mesh manually here), making it hard to debug. Also, avoid applying kinematic coupling to the whole workpiece, be careful with mass scaling and check all energy outputs.