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[m25mea001]

Hello,

I am currently learning LS-DYNA and trying to simulate an end milling operation with chip formation.

I have modelled the milling cutter as a rigid body and the workpiece as a deformable body. However, I am facing difficulties in defining the correct contact interaction required for material removal. The simulation also terminates with errors such as "Energy error too large" and "General solver error."

I have attached screenshots of my model setup, contact definition, and the solver errors.

Could anyone please guide me on:

• The recommended workflow for end milling simulations in LS-DYNA.

• The correct contact definition for chip formation.

• The essential Control Cards, Database Cards, and Keywords required for this type of simulation.

• Any official tutorials or benchmark examples for metal cutting using LS-DYNA.

Thank you for your time and guidance.

[Nanda]

Hello User,

This is one example I could find: LSDYNA Metal Cutting — Welcome to LS-DYNA Examples

From my understanding, this should be done in Implicit and not Explicit. I didn't go through this fully, but check if there's anything related discussed here: LS-DYNA Implicit Analysis Guide

Also a third party video which is quite old, but should be still relevant: Simulation of cutting using the ALE method in LS-DYNA. Video tutorial (incomplete)

Microsoft Word - FEM_dynamore.docx

I hope this helps. I don't have direct experience with Metal cutting in LS-DYNA. Perhaps someone else can chime in.

Regards,

Nanda.

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