An adaptive FEA method to predict surface quality in hard machining

A significant problem of studying surface integrity using FEA simulation is the severe element distortions on the machined surface. The severe distortions raise significant numerical problems in performing a simulation and analyzing surface integrity. In this study, adaptive meshing techniques of initial angle control (IAC) and mesh constraint control (MCC) were exploited to improve mesh quality of the machined surface. Simulations with and without adaptive meshing and different adaptive techniques were conducted and compared to evaluate their effectiveness on surface mesh quality. The simulation results have shown that the use of adaptive mesh in metal cutting simulations improves the stability of saw-tooth chip formation. Adaptive mesh can significantly mitigate element distortions, stresses, strains, and temperatures in the subsurface and therefore improve mesh quality. IAC and MCC adaptive meshing at high frequency give similar results which are consistent with experimental observations, while a low adaptive frequency tends to give deviated results. The importance of using adaptive mesh has been demonstrated if surface integrity is considered.