Title: Simulation research on ultra-precision cutting of mould steel with diamond tool

Authors: Xiaoguang Guo; Yanjun Wei; Zhuji Jin; Dongming Guo

Addresses: Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, Liaoning 116023, China. ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, Liaoning 116023, China. ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, Liaoning 116023, China. ' Key Laboratory for Precision and Non-traditional Machining Technology of Ministry of Education, Dalian University of Technology, Dalian, Liaoning 116023, China

Abstract: Conventional finite element methods are not able to deal with large deformation problems because of severe mesh distortion. And the smooth particle hydrodynamics (SPH) method can avoid this drawback, which is of mesh-free fashion and has an inherent advantage over the FEM methods in cutting simulations. In this paper, an SPH model of ultra-precision cutting is conducted using the LS-DYNA software. The orthogonal cutting process of AISI 4340 steel is simulated. It is revealed that cutting process is mainly performed by the rounded tool tip. During the cutting process, one part of the cutting layer is pushed forward to form the chip and the other part of cutting layer is extruded back into the bulk to form a smooth and dense surface. The simulation also gives an insight into changes of the temperature filed and the result implies cutting speed has a most notable effect on cutting temperature.

Keywords: ultra-precision cutting; mesh-free method; smooth particle hydrodynamics; SPH; numerical simulation; mould steel; diamond tools; orthogonal cutting; cutting speed; cutting temperature.

DOI: 10.1504/IJNM.2012.048584

International Journal of Nanomanufacturing, 2012 Vol.8 No.4, pp.326 - 339

Received: 14 Dec 2011
Accepted: 15 Mar 2012

Published online: 17 Aug 2012 *

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