Skip to main content
SpringerLink
Log in

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

  • Computer Aided Engineering
  • Published:
Production Engineering Aims and scope Submit manuscript

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.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

References

  1. Bagci E (2011) 3-D numerical analysis of orthogonal cutting process via mesh-free method. Int J Phys Sci 6:1267–1282

    Google Scholar 

  2. Belytschko T, Krongauz Y, Organ D, Fleming M, Krysl P (1996) Meshless methods: an overview and recent developments. Comput Methods Appl Mech Eng 139:3–47

    Article  MATH  Google Scholar 

  3. Brebbia CA, Telles JCF, Wrobel LC (1984) Boundary element techniques. Theory and applications in engineering. Springer, Berlin, p 464

    Book  MATH  Google Scholar 

  4. Cleary PW (1999) Modeling the high pressure die casting process using SPH. Second international conference on CFD in the minerals and process industries

  5. Cleary PW, Monaghan JJ (1999) Conduction modeling using smoothed particle hydrodynamics. J Comput Phys 148:227–264

    Article  MathSciNet  MATH  Google Scholar 

  6. Colagrossi A, Landrini M (2003) Numerical simulation of interfacial flows by smoothed particle hydrodynamics. J Comput Phys 191:448–475

    Article  MATH  Google Scholar 

  7. Das R, Cleary PW (2007) Modeling plastic deformation and thermal response in welding using smoothed particle hydrodynamics. 16th Australasian fluid mechanics conference, 2–7 December

  8. Groenenboom PHL, Lobovský L (2009) Artificial stress effects on structural dynamics using SPH. In: Proceedings of the 4th international SPHERIC SPH workshop, nantes, France, 27–29 May, pp 303–309

  9. Hallquist JO (2006) LS-DYNA theory manual livermore software technology corporation. J. O. Hallquist Livermore, California, 94551, p 680

  10. Heisel U, Krivoruchko DV, Zaloha VA, Storchak M (2007) Cause analysis of errors in FE prediction of orthogonal cutting performances. 10th CIRP international workshop on modeling of machining operations, pp 141–148

  11. Heisel U, Kryvoruchko DV, Zaloha VA, Storchak M, Stehle T (2009) Thermomechanische Wechselwirkungen beim Zerspanen. ZWF 4:263–272

    Google Scholar 

  12. Heisel U, Kryvoruchko DV, Zaloha VA, Storchak M, Stehle T (2009) Bruchmodelle für die Modellierung von Zerspanprozessen. ZWF 5:330–339

    Google Scholar 

  13. Heisel U, Storchak M, Eberhard P, Gaugele T (2011) Experimental studies for verification of thermal effects in cutting. Ann WGP Product Eng 5:507–515

    Article  Google Scholar 

  14. Jaspers SP (1999) Metal cutting mechanics and material behaviour. Technische Universiteit Eindhoven, Eindhoven, p 173

  15. Johnson GR, Cook WH (1985) Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures. Eng Fract Mech 21(1):31–48

    Article  Google Scholar 

  16. Krivoruchko DV (2010) Fundamental of cutting modeling with numerical methods. Thesis Dr. Sc. Tech., Kharkiv, p 40

  17. Lehnart A, Fleissner F, Eberhard P (2010) An alternative approach to modelling complex smoothed particle hydrodynamics boundaries. In: Proceedings of the 5th international SPHERIC SPH workshop, 23–25 June, Manchester, Great Britain, pp 21–28

  18. Limido J, Espinosa C, Salaün M, Lacome JL (2006) A new approach of high speed cutting modeling: SPH method. J Phys IV France 134:1195–1200

    Article  Google Scholar 

  19. Limido J, Espinosa C, Salaün M, Lacome JL (2007) SPH method applied to high speed cutting modeling. Int J Mech Sci 4:898–908

    Article  Google Scholar 

  20. Limido J, Espinosa C, Salaün M, Mabru C, Chieragatti R (2009) High speed machining modelling: SPH method capabilities. In: Proceedings of the 4th international SPHERIC SPH workshop, 27–29 May, Nantes, France, pp 116–122

  21. LS-DYNA keyword user’s manual volume imay (2007) version 971

  22. McDonald RP (1985) Factor analysis and related methods. Lawrence Erlbaum Associates, Hillsdale, p 262

  23. Rabczuk T, Belytschko T, Xiao SP (2004) Stable particle methods based on Lagrangian kernels. Comput Methods Appl Mech Eng 193:1035–1063

    Article  MathSciNet  MATH  Google Scholar 

  24. Ricardo LA, Alves M (2009) Numerical simulation of soft-body impact on GFRP laminate composites: mixed SPH-FE and pure SPH approaches. Mech Solids Brazil:15–30

  25. Ruttimann N, Buhl S, Wegener K (2010) Simulation of single grain cutting using SPH method. J Mach Eng 10:17–29

    Google Scholar 

  26. Shah QH, Hamdani A (2013) The damage of unconfined granite edge due to the impact of varying stiffness projectiles. Int J Impact Eng 59:11–17

    Article  Google Scholar 

  27. Stein E, De BR, Hughes TJ (2004) Encyclopedia of computational mechanics in 2 vol—Chichester. Wiley, New York, p 798

  28. Su C, Xu L, Liu Y, Ma J (2013) Numerical simulation of cutting process of CBN grit based on SPH method. J China Mech Eng 24:667–671

    Google Scholar 

  29. Zenkevich OC, Morgan K (1983) Finite elements and approximation. Wiley, NY, p 318

    Google Scholar 

Download references

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”.

Author information

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
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Wiliam Zaloga
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Dmitrii Krivoruchko
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Michael Storchak
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Liubov Goloborodko
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Michael Storchak.

Rights and permissions

Reprints and permissions

About this article

Cite this article

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

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

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

Keywords

Search

Navigation