Machining Process Simulations with Smoothed Particle Hydrodynamics

Abstract Because of its meshless nature, the Smoothed Particle Hydrodynamics (SPH) method is a promising alternative to well-established mesh-based simulation techniques like the Finite Element Method when investigating setups that are characterized by a highly dynamic behavior as well as large deformations of the initial configuration. This is typically the case for machining processes. First, a brief introduction to the basic principle of the SPH discretization formalism is provided. Second, the extensions to the original SPH solid scheme that are necessary to model the process of metal cutting in an appropriate way, i.e., to take into account, among other things, the thermal aspects of the problem, are introduced. Besides, emphasis is placed on the local adaptive resolution strategy that has been developed and helps to improve the accuracy of the simulation results while reducing the required computational cost at the same time. The main focus of this paper is on the capability of the extended SPH solid model to describe real machining processes in simulations. Here, we demonstrate that the employed discretization method is able to reproduce the behavior of a processed workpiece observed in experiments by analyzing and, subsequently, assessing the obtained simulation results in terms of chip morphology, stress and temperature distribution, as well as cutting force. For validation purposes, we compare the results found from both simple two- and fully three-dimensional simulations with experimental data for steel C45E.