Simulation of Metal Cutting using Smooth Particle Hydrodynamics

Summary: The purpose of this study is to introduce an approach of metal cutting simulation. A Smooth Particle Hydrodynamics (SPH) based model is carried out using the LS-DYNA software. SPH is a meshless method which is very promising as a numerical method for modelling problems involving large deformations such as metal cutting. Predicted cutting forces are compared with results from experiments. Series of sensitivity analyses were performed in order to evaluate the SPH based model. The model’s sensitivity to changes of different parameters was examined. Experimental measuring of the cutting forces was performed with Kistler dynanometer type 9257BA. The numerical simulations were performed with the explicit finite element code LS-DYNA Ver. 971. rev. 7600.1224. A good agreement between the predicted and measured cutting forces was observed. The chip formation was also predicted well. The results of the analyses are: the cutting force was underestimated by 8.4% and the thrust force was underestimated by 12% when compared with measured forces from experiments.

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