Bolt head trimming is a fast, complicated cutting process including material failure. For this reason, explicit solver LS-Dyna was used for its simulation. The aim of the simulation was to minimize the loading of the trimming matrix, so that its durability could be enhanced. Three geometrical versions were solved and the results were compared with respect to the cutting work and contact force. As the reliability of the computational model can be questionable, an experiment was carried out to verify the computational results. Cutting force, shape of trimmed areas and distribution of plastic deformation and shear bands were compared with the computational results.
Three ductile fracture models are presented and applied to simulation of industrial process of bolt head trimming. Numerical simulation is compared with the results of experimental measurement and metalographic analysis of specimens, processed in semi-industrial conditions. Dominant influence of the stress triaxialiry on the predictive reliability of individual fracture criteria in the conditions of shear and shear with compression is documented by the results.
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