Assessment of finite element and smoothed particles hydrodynamics methods for modeling serrated chip formation in hardened steel

Abstract

This study aims to perform comparative analyses in modeling serrated chip morphologies using traditional finite element and smoothed particles hydrodynamics methods. Although finite element models are being employed in predicting machining performance variables for the last two decades, many drawbacks and limitations exist with the current finite element models. The problems like excessive mesh distortions, high numerical cost of adaptive meshing techniques, and need of geometric chip separation criteria hinder its practical implementation in metal cutting industries. In this study, a mesh free method, namely, smoothed particles hydrodynamics, is implemented for modeling serrated chip morphology while machining AISI H13 hardened tool steel. The smoothed particles hydrodynamics models are compared with the traditional finite element models, and it has been found that the smoothed particles hydrodynamics models have good capabilities in handling large distortions and do not need any geometric or mesh-based chip separation criterion.

Modeling of Ti6Al4V Alloy Orthogonal Cutting with Smooth Particle Hydrodynamics: A Parametric Analysis on Formulation and Particle Density

“…In [24], a model of the same type is used for the prediction of the variation of cutting forces caused by a worn cutting tool. In [25][26][27][28][29][30], SPH models of orthogonal, or oblique, cutting are created where the cutting tool is modeled with finite elements and the workpiece with SPH particles, which means that a friction model had to be used. In [30], the effect of subsequent cuts on the evolution of residual stresses in the workpiece is presented.…”

“…One of these formulations is called renormalization and more details about its foundations and development can be found in [37,38]. Orthogonal cutting simulations with SPH can be found in the literature [23][24][25][26][27][28][29][30][31][32][33][34][35] for different formulations. However, there are no studies that examine the influence of the chosen formulation, on the prediction of the cutting forces.…”

A Study of Explicit Numerical Simulations in Orthogonal Metal Cutting

“…The grid moves during the simulation to optimize the element shape independently of the material deformation. The SPH method does not need a mesh and the grid of the model is defined by a number of particles oriented at specific distance from each other having a pure Lagrangian formulation [3][4][5][6][7][8].…”

“…In order to explore the capabilities of SPH, FEM and ALE explicit methods and choose the most suitable for the simulation of the experimental cut of AISI 1045, these three methods are used to simulate the orthogonal cut of steel AISI H13 by Polycrystalline Cubic Boron Nitride (PCBN). The cutting of AISI H13 by PCBN is a well-studied experimental case found in the literature [8,9] that may outline the advantages and disadvantages of each of the three numerical methods. Τhe J-C constitutive strength material model is chosen for the study of the dynamic elastoplastic behavior of the workpiece material and J-C damage law is adopted in all simulations, performed by the help of the commercial software LS-DYNA [10].…”

“…The accuracy of the approximated cutting forces from these three methods compared to the literature results is the main criterion for the performance of the methods. Stress, strain and temperature distributions are also computed and compared to literature results [3,[7][8][9]. Furthermore, the model development complexity and the computational time demands for each model are taken into account, so as to draw safe conclusions for the overall performance of the studied methods.…”