ABSTRACT:

Numerical rock cutting simulations are performed for different cutter configurations. Special attention is given to the contact region between the cutter and the rock. Frictional contact is solved using a Gap Based Augmented Lagrangian approach, in order to minimize the interpenetration error that is present in the less expensive penalty approach, while reducing finite element accumulation time compared to the standard Lagrangian method. Numerical experiments are performed with a single cylindrical cutter of radius 16 mm, a back rake of 15°, a depth of cut of 4 mm, and two different chamfers: a 0.3 mm chamfer at 15°, and a 0.5 mm chamfer at 45°. The number of Uzawa iterations required for the interpenetration error to have minimal impact on cutting forces is estimated, and the accuracy of the penalty approach is emphasized. Contact tractions are shown, suggesting areas where the mesh should be refined. A suitable mesh size is given for both chamfer geometries. The influence of the friction coefficient on cutting forces is evaluated, suggesting a cutter configuration insensitive to the value of the friction coefficient within a realistic range.

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