Abstract A meshless generalized interpolation material point method for simulating the micro-milling process was developed. This method has several advantages over well-established approaches (such as finite elements) when it comes to large plastic strains and deformations, since it inherently does not suffer from tensile instability problems. The feasibility of the developed material point model for simulating micro-milling is verified against finite element simulations and experimental data. The model is able to successfully predict experimentally measured cutting forces and determine chip temperatures in agreement with conventional finite element simulations. After having verified the approach, the model was applied to perform extensive numerical 3D simulations of the micro-milling process. The goal is to evaluate the response of the micro-milling cutting forces as function of the hardening behavior of the micro-milled material. The meshless 3D simulations reveal a dependency of tool force slopes (with respect to the uncut chip thickness) on the hardening parameters. Based on these findings, a new approach is outlined to determine hardening parameters directly from two micro-milling experiments with distinct, sufficiently large uncut chip thicknesses.

中文翻译：

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用于模拟微铣削过程的无网格 3D 材料点方法的开发和验证

摘要 开发了一种用于模拟微细铣削过程的无网格广义插值材料点方法。当涉及到大的塑性应变和变形时，这种方法比成熟的方法（例如有限元）有几个优点，因为它本质上不会受到拉伸不稳定问题的影响。通过有限元模拟和实验数据验证了所开发的用于模拟微铣削的材料点模型的可行性。该模型能够成功预测实验测量的切削力，并与传统的有限元模拟一致地确定切屑温度。在验证了该方法之后，该模型被应用于对微铣削过程进行广泛的数值 3D 模拟。目标是评估作为微铣削材料硬化行为函数的微铣削切削力的响应。无网格 3D 模拟揭示了刀具力斜率（相对于未切削切屑厚度）对硬化参数的依赖性。基于这些发现，概述了一种新方法，可以直接从具有不同的、足够大的未切削切屑厚度的两个微铣削实验中确定硬化参数。