Discretization approaches to model orthogonal cutting with Lagrangian, Arbitrary Lagrangian Eulerian, Particle Finite Element method and Smooth Particle Hydrodynamics formulations

Abstract

With significant technological growth and computational power, it is possible to simulate metal cutting processes with increased complexity. In the modeling phase, a fundamental question about choosing the best discretization approach arises. Lagrangian and Eulerian formulations are the two classical discretization approaches. Alternative methods to these mesh-based approaches are being developed in recent times, such as particle-based and meshless methods. In this work, we employed four discretization approaches: pure Lagrangian (LAG), Arbitrary Lagrange Eulerian (ALE), Particle Finite Element Method (PFEM) and Smooth Particle Hydrodynamics (SPH), to simulate a turning operation of AISI 4140 steel. This paper aims to compare the conventional approaches (LAG and ALE) to newer approaches (PFEM and SPH). Firstly, orthogonal cutting models were benchmarked against a turning experiment presented in the literature, by comparing the obtained cutting and passive forces. Secondly, a detailed comparative study of parameters, such as forces, stresses, temperatures, chip morphology etc. of the four discretization approaches was performed. The study was then extended to negative rake angles to study the effect on the discretization approaches. The work concludes with identifying the advantages and drawbacks of different discretization approaches.