Abstract
This paper presents the first application of a higher-order Smoothed Particle Hydrodynamics (SPH) method to the thermal modeling of metal cutting problems. With this application, the heat transfer equation in the thermo-mechanical simulation of metal cutting is solved more accurately by addressing the consistency issue of standard SPH formulations. Furthermore, through a robust and effective surface-detection algorithm, this work enables the SPH cutting models to include heat loss thermal boundary conditions for the first time. Process forces, tool temperatures, and chip geometry are numerically investigated in machining a Ti6Al4V workpiece at two different cutting speeds. Several validation tests and sensitivity analyses are performed in high resolution, thanks to the runtime acceleration of SPH by parallel computing on Graphics Processing Units (GPUs). The results show that SPH simulations with the proposed thermal modeling approach achieve more realistic serrated chips in titanium cutting problems.
Highlights
Numerical simulation of metal cutting with meshfree methods began in the late 90s and has been a continuing activity ever since
As a meshfree Lagrangian approach suitable for complex flows and large-deformation problems, Smoothed Particle Hydrodynamics (SPH) has proven successful for chip formation simulations of metal cutting processes, too
A graphical illustration of the orthogonal cutting problem displayed in Fig. 1 shows chip formation as a result of the toolworkpiece contact at the rake face
Summary
Numerical simulation of metal cutting with meshfree methods began in the late 90s and has been a continuing activity ever since. Afrasiabi et al [8] provided an efficient SPH framework (with dynamic particle refinement) for the thermomechanical analysis of metal cutting by studying the effect of spatial discretization size on the chip morphology They solve the heat conduction equation throughout the workpiece by assuming adiabatic boundary conditions; their thermal modeling approach lacks three components. With a particular emphasis on in-house codes and runtime acceleration through parallel processing, Roethlin and his coworkers in their two successive papers, Röthlin et al [9]and Roethlin et al [10], developed a new SPH-based software tool for 2D and 3D metal cutting applications and resolved the three problems mentioned before These recent efforts address the heat transfer issue from the workpiece to the tool in SPH models.
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