Modeling of Metal Cutting Processes Within the Material Point Method Using the Johnson–Cook Material Law

ABSTRACT The material point method represents an alternative approach to simulations, differing from traditional methods like the finite element method (FEM). This technique involves discretizing bodies using material points while solving equations on a separate computational grid where each time step comprises three steps. Initially, the kinematic quantities of the material points are transferred to the grid nodes. Subsequently, computations are carried out on these nodes, with the results then reassigned to the material points, updating their position, velocity, stress as well as deformation state. After each time step, the previous grid is discarded as it does not rely on persistent information. As a result, a new grid is initialized in each time step, avoiding the risk of mesh distortion in the case of huge deformations, a common drawback arising in FEM analyses. This contribution presents simulations of three‐dimensional metal cutting processes utilizing the Johnson–Cook material law to accommodate for plastic strain rates and heat generated by plastic deformations. Additionally, the grid‐shift technique is employed to reduce oscillations and enhance robustness of the simulations.