The purpose of this study is to introduce a new approach of high speed cutting numerical modelling. A Lagrangian smoothed particle hydrodynamics (SPH)-based model is carried out using the Ls-Dyna software. SPH is a meshless method, thus large material distortions that occur in the cutting problem are easily managed and SPH contact control permits a ''natural'' workpiece/chip separation. The developed approach is compared to machining dedicated code results and experimental data. The SPH cutting model has proved is ability to account for continuous to shear localized chip formation and also correctly estimates the cutting forces, as illustrated in some orthogonal cutting examples. Thus, comparable results to machining dedicated codes are obtained without introducing any adjusting numerical parameters (friction coefficient, fracture control parameter).

Abstract. The modeling of fragmentation has historically been linked to the weapons industry where the main goal is to optimize a bomb or to design effective blast shields. Numerical modeling of fragmentation from dynamic loading has traditionally been modeled by legacy finite element solvers that rely on element erosion to model material failure. However this method results in the removal of too much material. This is not realistic as retaining the mass of the structure is critical to modeling the event correctly. We propose a new approach implemented in the IMPETUS AFEA SOLVER R based on the following: New High Order Finite Elements that can easily deal with very large deformations; Stochastic distribution of initial damage that allows for a non homogeneous distribution of fragments; and a Node Splitting Algorithm that allows for material fracture without element erosion that is mesh independent. The approach is evaluated for various materials and scenarios: -Titanium ring electromagnetic compression; Hard steel Taylor bar impact, Fused silica Taylor bar impact, Steel cylinder explosion, The results obtained from the simulations are representative of the failure mechanisms observed experimentally. The main benefit of this approach is good energy conservation (no loss of mass) and numerical robustness even in complex situations.

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Energy absorption during crushing is evaluated using a thermodynamic based continuum damage model inspired from the Matzenmiller-Lubliner-Taylors model. It was found that for crash-worthiness applications, it is necessary to couple the progressive ruin of the material to a representation of the matter openings and debris generation. Element kill technique (erosion) and/or cohesive elements are efficient but not predictive. A technique switching finite elements into discrete particles at rupture is used to create debris and accumulated mater during the crushing of the structure. Switching criteria are evaluated using the contribution of the different ruin modes in the damage evolution, energy absorption, and reaction force generation.

The purpose of this work is to evaluate the use of the smoothed particle hydrodynamics (SPH) method within the framework of high speed cutting modelling. First, a 2D SPH based model is carried out using the LS-DYNA® software. The developed SPH model proves its ability to account for continuous and shear localised chip formation and also correctly estimates the cutting forces, as illustrated in some orthogonal cutting examples. Then, the SPH model is used in order to improve the general understanding of machining with worn tools. At last, a hybrid milling model allowing the calculation of the 3D cutting forces is presented. The interest of the suggested approach is to be freed from classically needed machining tests: Those are replaced by 2D numerical tests using the SPH model. The developed approach proved its ability to model the 3D cutting forces in ball end milling.