Numerical modeling of cutting force and chip formation during water Jet Assisted Machining of Ti17 based on SPH/FEM method

Abstract

In this paper, we conduct a numerical simulation of a water jet-assisted machining process for a titanium alloy Ti17, with a focus on addressing the Fluid-Structure Interaction (FSI) problem arising during lubricated machining. The proposed coupling strategy employs the Smoothed Particle Hydrodynamics (SPH) free mesh method, coupled with an ordinary Lagrangian mesh. The SPH method is utilized to model the water jet, while the Lagrangian Finite Element Method (FEM) is employed to represent the workpiece and the tool. The hydrodynamic behavior of water is captured using the linear Huguenot form of the Mie-Greisen equation of state. Additionally, the Johnson-Cook constitutive law is applied to describe the thermoviscoplastic behavior of the titanium alloy. It is essential to note that thermal and mechanical effects were decoupled in this study. The investigation focuses on cutting force and chip morphology under two distinct cutting regimes: Dry Machining (DM) and Water Jet Assisted Machining, specifically with conventional lubrication (CL). The numerical simulations are compared with experimental results found in the literature, with an emphasis on cutting force and chip morphology. The obtained simulation results exhibit a favorable correlation with the experimental data. All numerical simulations were conducted using ABAQUS version 6.14.