Investigation of Stress State by Numerical Simulation of 3D Manufacturing Processes

This chapter delves into the numerical simulation of 3D manufacturing processes, specifically shearing and machining of Al7075-T6 bars. The study focuses on analyzing stress states and geometric defects, their influence on tool lifespan, and the overall product quality. Key topics include the investigation of ductile failure and stress states in the fracture zone, the impact of shear clearance and shear rate on the geometry of the shear surface, and the influence of geometric defects on workpiece temperature evolution. The research employs finite element modeling using ABAQUS/Explicit and the Johnson-Cook damage model to predict damage in cutting processes. The findings reveal that higher shear rates and clearances correlate with increased geometric imperfections, and that geometric defects can lead to elevated temperatures and faster tool wear. This comprehensive analysis provides valuable insights into optimizing manufacturing processes to enhance product quality and tool longevity.