Metal cutting modelling SPH approach

Abstract

The purpose of this work is to evaluate the use of the smoothed particle hydrodynamics (SPH) method within the framework of high speed cutting modelling. First, a 2D SPH based model is carried out using the LS-DYNA® software. The developed SPH model proves its ability to account for continuous and shear localised chip formation and also correctly estimates the cutting forces, as illustrated in some orthogonal cutting examples. Then, the SPH model is used in order to improve the general understanding of machining with worn tools. At last, a hybrid milling model allowing the calculation of the 3D cutting forces is presented. The interest of the suggested approach is to be freed from classically needed machining tests: Those are replaced by 2D numerical tests using the SPH model. The developed approach proved its ability to model the 3D cutting forces in ball end milling.

Modeling of Ti6Al4V Alloy Orthogonal Cutting with Smooth Particle Hydrodynamics: A Parametric Analysis on Formulation and Particle Density

“…The usage of the renormalized formulation leads to the production of a more realistic chip. The nonrealistic chip curvature of the standard formulation is attributed to the absence of particles in the exterior areas of the boundaries of the solution domain (workpiece) [36]. This absence leads to non-approximate calculations near the boundaries.…”

“…One of the deficiencies of the SPH method in metal cutting simulations is the inability of prediction of a realistic chip curvature, as it is mentioned in [36]. For this reason, alternative formulations are proposed to the standard SPH scheme, where this issue is resolved.…”

Investigation of chip formation mechanism in ultra-precision diamond turning of silk fibroin film

“…Another advantage of SPH is the natural chip/workpiece separation [30]. There is no need to introduce the chip separation criterion (as required in Lagrangian approach) or a pre-defined cutting path to enable the chip/workpiece separation.…”

Numerical study via total Lagrangian smoothed particle hydrodynamics on chip formation in micro cutting

“…Thus, the total Lagrangian SPH (TLSPH) is being developed [17], and ''hourglass control'' is employed to eliminate zero-energy modes [18]. In cutting simulations performed using conventional SPH, sources of instability, such as non-uniform particle distribution and low cutting speed, have been reported [19]. Influences of both the material model and the SPH parameters on simulation result have also been discussed [20,21].…”