Title: Metal cutting modelling SPH approach

Authors: J. Limido, C. Espinosa, M. Salaun, C. Mabru, R. Chieragatti, J.L. Lacome

Addresses: IMPETUS Advanced Finite Element Analysis, rue du Lanoux, 31330 Grenade sur Garonne, France. ' Universite de Toulouse, INSA,UPS, Mines Albi, ISAE; Institut Clement Ader, 10 av. Edouard Belin, F-31055 Toulouse, France. ' Universite de Toulouse, INSA,UPS, Mines Albi, ISAE; Institut Clement Ader, 10 av. Edouard Belin, F-31055 Toulouse, France. ' Universite de Toulouse, INSA,UPS, Mines Albi, ISAE; Institut Clement Ader, 10 av. Edouard Belin, F-31055 Toulouse, France. ' Universite de Toulouse, INSA,UPS, Mines Albi, ISAE; Institut Clement Ader, 10 av. Edouard Belin, F-31055 Toulouse, France. ' LSTC, rue du Lanoux, 31330 Grenade sur Garonne, France

Abstract: 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.

Keywords: high speed machining; smoothed particle hydrodynamics; SPH; chip formation; tool wear; ball end milling; metal cutting; modelling; 3D cutting forces.

DOI: 10.1504/IJMMM.2011.039645

International Journal of Machining and Machinability of Materials, 2011 Vol.9 No.3/4, pp.177 - 196

Published online: 13 Apr 2011 *

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