Metal cutting simulations using smoothed particle hydrodynamics on the GPU

Röthlin, Matthias; Klippel, Hagen; Afrasiabi, Mohamadreza; Wegener, Konrad

doi:10.1007/s00170-019-03410-0

Cited by 28 publications

(30 citation statements)

References 39 publications

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“…in which k is the heat conductivity assuming an isotropic heat conduction, c p the specific isobaric heat capacity, including the source terms Q plast and Q fric due to the conversion of the plastic and frictional work. According to the works in [17,23], these heat sources are computed from…”

Section: Governing Equationsmentioning

confidence: 99%

“…In Section 5, the values of five JC parameters (A, B, C, m, and n) will be provided for the titanium alloy under consideration. For friction modeling, Coulomb's law with a constant coefficient of µ = 0.35 is considered as a typical choice in LS-DYNA [13] and other SPH cutting models like [17], unless otherwise mentioned. As the magnitude of µ has a significant impact on the force prediction of numerical cutting models (see in [19,26] for more details), a sensitivity analysis will be presented to provide further insights into the influence of the friction coefficient on simulation results.…”

Section: Governing Equationsmentioning

confidence: 99%

“…These papers do not consider the heat transfer from the workpiece to the tool, while the experimental evidence has shown that a significant proportion of heat in metal machining operations transfers from the chipping zone to the cutting tool [16]. More recently, the concept of parallel computing on Graphics Processing Units (GPU) has been introduced to both 2D [17] and 3D [18] SPH cutting simulations to boost the computational performance. Afrasiabi et al [19] employed this GPU-accelerated approach for inverse parameter identification and proposed a temperature-dependent coefficient of friction in SPH cutting models.…”

Section: Introductionmentioning

confidence: 99%

“…Although previous studies have demonstrated some excellent results in the capability of SPH to simulate metal cutting processes, none of them accounts for heat loss boundary conditions in their thermal model. More specifically, the issue with ignoring the heat transfer from the workpiece to the tool in SPH models (e.g., in [13,20]) was addressed by some recent works in [17,19]. However, the thermal modeling approach in these papers also suffers from two shortcomings: (1) Utilizing an inconsistent Laplacian operator that deteriorates the solution accuracy near the boundaries.…”

Section: Introductionmentioning

confidence: 99%

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Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

et al. 2021

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Smoothed Particle Hydrodynamics (SPH) is a mesh-free numerical method that can simulate metal cutting problems efficiently. The thermal modeling of such processes with SPH, nevertheless, is not straightforward. The difficulty is rooted in the computationally demanding procedures regarding convergence properties and boundary treatments, both known as SPH Grand Challenges. This paper, therefore, intends to rectify these issues in SPH cutting models by proposing two improvements: (1) Implementing a higher-order Laplacian formulation to solve the heat equation more accurately. (2) Introducing a more realistic thermal boundary condition using a robust surface detection algorithm. We employ the proposed framework to simulate an orthogonal cutting process and validate the numerical results against the available experimental measurements.

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Section: Governing Equationsmentioning

confidence: 99%

Section: Governing Equationsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

et al. 2021

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“…The methods supported by a mesh include the Multi-material Eulerian Method (MMEM) [13,14], the Volume of Solid (VOS) [15], and the Material Point Method (MPM) or Point in Cell (PiC) method [16,17]. Among the particles/meshless methods applied to metal cutting we found: the Smoothed Particle Hydrodynamics (SPH) [18,19], the Finite Point Method (FPM) [20], the Constrained Natural Element Method (CNEM) [21], the Discrete Element Method (DEM) [22], the Maximum Entropy MeshFree method [23], the stabilized optimal transportation meshfree method (OTM) [24], and the Particle Finite Element Method (PFEM) [25][26][27][28]. Most of these new methods are applied using similar simplified models.…”

Section: Introductionmentioning

confidence: 99%

Dislocation Density Based Flow Stress Model Applied to the PFEM Simulation of Orthogonal Cutting Processes of Ti-6Al-4V

et al. 2020

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Machining of metals is an essential operation in the manufacturing industry. Chip formation in metal cutting is associated with large plastic strains, large deformations, high strain rates and high temperatures, mainly located in the primary and in the secondary shear zones. During the last decades, there has been significant progress in numerical methods and constitutive modeling for machining operations. In this work, the Particle Finite Element Method (PFEM) together with a dislocation density (DD) constitutive model are introduced to simulate the machining of Ti-6Al-4V. The work includes a study of two constitutive models for the titanium material, the physically based plasticity DD model and the phenomenology based Johnson–Cook model. Both constitutive models were implemented into an in-house PFEM software and setup to simulate deformation behaviour of titanium Ti6Al4V during an orthogonal cutting process. Validation show that numerical and experimental results are in agreement for different cutting speeds and feeds. The dislocation density model, although it needs more thorough calibration, shows an excellent match with the results. This paper shows that the combination of PFEM together with a dislocation density constitutive model is an excellent candidate for future numerical simulations of mechanical cutting.

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Contact framework for total Lagrangian smoothed particle hydrodynamics using an adaptive hybrid kernel scheme

Wiragunarsa,

Zuhal,

Dirgantara

et al. 2024

Numerical Meth Engineering

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Total Lagrangian SPH (TLSPH) offers many advantages that can overcome instability and computational time issues. However, it is not naturally applicable to problems with contact. Many problems in solid dynamics and structural analysis require contact definition. In order to use the total Lagrangian formulation, further development for the contact algorithm is required. This research proposes an algorithm to implement inter‐particle contact in TLSPH using an adaptive hybrid‐kernel scheme for the first time. A combination of the updated and total Lagrangian formulations at the contact surface is introduced, in which the kernel type change automatically when particles from a different body are detected. In kernel change from the updated to the total Lagrangian formulation, the gradient correction cannot be performed using a common correction method because different frames of reference are used. Therefore, a hybrid‐kernel correction technique is proposed to maintain the zeroth‐ and first‐order completeness. Then, the contact force is obtained from the inter‐particle force using the conservation of momentum. The proposed method does not require a user‐defined parameter that makes the application straightforward. Based on the test, the proposed method agrees well with the data available in published literature and the finite element method. Compared with the contact method in classical SPH, the proposed TLSPH shows a significant stability improvement.

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Metal cutting simulations using smoothed particle hydrodynamics on the GPU

Cited by 28 publications

References 39 publications

Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

Dislocation Density Based Flow Stress Model Applied to the PFEM Simulation of Orthogonal Cutting Processes of Ti-6Al-4V

Contact framework for total Lagrangian smoothed particle hydrodynamics using an adaptive hybrid kernel scheme

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