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Modelling of orthogonal cutting processes with the method of smoothed particle hydrodynamics

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Abstract

In the last decades, mesh-free methods for simulating various cutting processes have been used very widely as they can eliminate numerical problems in the simulation of material failure and large plastic deformations. This paper deals with the results from modelling the orthogonal cutting of AISI 1045 steel using smoothed particle hydrodynamics (SPH) method. Moreover, it is determined how the parameters of the SPH solver such as initial smoothing length, initial particle density and coefficient for the timestep increase affect the prediction error for the values of cutting force and chip compression ratio as well as computing time. The optimum values of the SPH solver parameters are determined by minimising an objective function. The best balance between the prediction error of machining variables and computing time is achieved for an initial particle density of 40 μm and a coefficient for the timestep increase of 0.4.

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Acknowledgments

The presented results were gained in the project HE 1656/146-1 “Modelling and Compensation of Thermic Processing Influence for Short Hole Drilling” within the priority program SPP 1480 “Modelling, Simulation and Compensation of Thermal Effects for Complex Machining Processes” (CutSim), which was funded by the German Research Foundation (DFG). This support is highly appreciated, and the authors would like to thank the DFG and all partners in this SPP. The authors also thank the Ministry of Education and Science of Ukraine for the support of research in the framework of the project 0112U001377 “Study of holes machining in composite materials and mixed packets based on simulation of cutting processes”.

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Authors and Affiliations

  1. Institute for Machine Tools, University of Stuttgart, Holzgartenstraße 17, 70174, Stuttgart, Germany

    Uwe Heisel & Michael Storchak

  2. Department of Manufacturing Engineering, Sumy State University, Rimskogo-Korsakova-Str. 2, Sumy, 40007, Ukraine

    Wiliam Zaloga, Dmitrii Krivoruchko & Liubov Goloborodko

Authors
  1. Uwe Heisel
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  2. Wiliam Zaloga
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  3. Dmitrii Krivoruchko
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  4. Michael Storchak
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  5. Liubov Goloborodko
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Correspondence to Michael Storchak.

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Heisel, U., Zaloga, W., Krivoruchko, D. et al. Modelling of orthogonal cutting processes with the method of smoothed particle hydrodynamics. Prod. Eng. Res. Devel. 7, 639–645 (2013). https://doi.org/10.1007/s11740-013-0484-0

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  • DOI: https://doi.org/10.1007/s11740-013-0484-0

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