On the SPH Orthogonal Cutting Simulation of A2024-T351 Alloy

Abstract

Smoothed Particle Hydrodynamics (SPH) is known for its ability to simulate a natural flow of material without mesh distortion problems related to the Finite Element Method (FEM) frequently. Therefore it can be used to simulate material flow around the tooltip in machining simulations.This paper presents some results of the SPH orthogonal cutting simulations of A2024-T351 aluminium alloy compared to the experimental and FEM simulation results published by Mabrouki et al. recently. Simulations were performed with the ANSYS LS- DYNA solver. To simulate the workpiece behavior during cutting, the Johnson-Cook constitutive material model was used. In this work, an influence of the Johnson-Cook failure parameters D1-D5 and SPH density on a saw-toothed chip formation was observed. Chip shapes, von Mises stress, plastic strains, strain rates and cutting forces were compared to published results, confirming that the SPH method is able to predict the cutting and feed forces and the chip shape correctly. For experimental verification, a CNC machine, dry cutting, uncoated cemented carbide inserts ISO N10-20, cutting speeds in the range of 200-800 m/min, feed 0.4mm and depth of cut 4.0mm were used. Regarding the SPH particles density it was found that the model with smaller space among particles tended to form a highly segmented chip. However, for a good correlation with experimental results the Johnson-Cook failure parameters together with minimum required strain for failure should be set.