Smoothed Particle Hydrodynamics Simulation of Orthogonal Cutting with Enhanced Thermal Modeling

Abstract

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.

A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

“…More importantly, none of these papers provides experimental validation of thermal loads. Although Afrasiabi et al [40] have recently taken the first step to fill this gap, there are some issues in their results that still need to be addressed. Firstly, the experimental validation of thermal loads was adapted from other work and reported only for the rake face temperature.…”

“…Firstly, the experimental validation of thermal loads was adapted from other work and reported only for the rake face temperature. Secondly, the simulation results presented in [40] are low resolution (as the SPH runtime is not accelerated) and taken only after a cut distance of 0.3 mm, which seems insufficient to establish a steady-state temperature distribution. The very recent publication of [41] addresses these issues and presents a complete thermal model for metal cutting simulation.…”

“…The thermal contact are thus naturally handled via the SPH particle-particle interaction. To find the boundary particles for imposing the thermal boundary condition, the enhanced scheme of [40] was employed. This newly proposed thermal modeling approach incorporates a free-surface detection algorithm to identify the interface particles.…”

Archives of Foundry Engineering

“…Therefore, it is hoped that in the future the 3D SPH model will be focused on, researched, and applied to specifically solve problems in HSCP (free surface, friction, heat exchange). Besides, Afrasiabi et al [104] also used the SPH method to numerically simulate the orthogonal metal cutting process with an advanced thermal model. The numerical analysis includes both thermal and mechanical effects to solve thermal equations and examine the elastic properties of materials.…”

Thermomechanical Simulation of Orthogonal Metal Cutting with PFEM and SPH Using a Temperature-Dependent Friction Coefficient: A Comparative Study

“…The vast majority of these papers do do not consider heat transfer between bodies or consider that the friction coefficient is constant. A friction coefficient dependent on the temperature and relative velocity was proposed in [ 12 , 47 ]. Previous research shows that including the dependence of friction on temperature and relative velocity improves the prediction of process forces and temperatures.…”