3-D numerical analysis of orthogonal cutting process via mesh-free method

In this paper, the applications of mesh-free SPH (Smoothed Particle Hydrodynamics) methodology to the simulation and analysis of 3-D hard machining process is presented. A Langrangian SPH based model is carried out using the Ls-Dyna software. Classical Lagrangian, Eulerian and ALE methods such as finite element methods (FEM) cannot resolve the large distortions very well. Conventional finite element analysis of metal cutting processes often breaks down due to severe mesh distortion. Recent developments in so called mesh-free or meshless methods provide alternates for traditional numerical methods in modeling the machining processes. SPH is a mesh-free approach, so large material deformations that happen in the analysis of cutting problem are easily managed and SPH contact control permits an “inherent” chip/workpiece separation. Because SPH combines the advantages of mesh-free, langrangian, particle methods, an alternative methodology, which appears to eliminate most of those difficulties is that of meshless methods. The orthogonal cutting process of AISI H13 steel material was modeled and analysed using SPH method. The developed SPH model gained its ability to correctly estimate the cutting forces, as illustrated in two orthogonal cutting situations. Cutting forces were compared for SPH, Langrangian explicit  and experimental results. The predicted (SPH) cutting forces agree within 8.43% and 11.70% of the measured values for tangential and normal components respectively. A good agreement between predicted and experimental cutting forces was observed.   Key words: Machining, cutting, mesh-free methods, meshless, SPH, Eulerian, ALE, Langrangian