Abstract
This paper conducts a parametric numerical study of the orthogonal cutting process using the state-of-the-art smoothed particle hydrodynamics (SPH) method. In this work, special attention was paid to the effects of tool edge radius, tool rake angle, particle density, smoothing length and damage criterion on the cutting process. Orthogonal cutting experiments and corresponding numerical simulations were conducted, and the comparison of experimental and simulation results confirmed that the SPH model developed herein can be used for subsequent parametric investigation of orthogonal cutting processes. The results reveal that significant increases are observed in chip curvature with the increase of particle density. A higher particle density produces a smoother cutting force profile, while the particle density has a slight effect on the cutting force value. SPH requires no damage definition, and the natural separation of particles is capable of producing a reasonable cutting force and chip morphology. In addition, a larger smoothing length, which is twice the particle spacing, will lead to numerical instability. This work will pave the way for SPH application in machining simulations.
Published Version
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