Implementation of MC-SPG Particle Method in the Simulation of Orthogonal Turning Process

In the automotive industry, due to fast changing markets and push for implementing novel materials, competitiveness relies increasingly on economical and short planning cycles of machining process. Digitalization has created opportunities for automotive industries to reduce time to market with the help of computer simulations of manufacturing process. In the past decade, particle methods like Smooth Particle Hydrodynamics (SPH), and Smooth Particle Galerkin (SPG), among many others, have been used to simulate machining process. The particle methods have an advantage over classical Finite Element Methods (FEM) as particle methods do not require remeshing or continuous mesh adaptation. Thus, particle methods eliminate the mesh entangling problems in simulation of large plastic deformations, such as machining. This paper describes the application of original SPG and the new Momentum-Consistent-SPG (MC-SPG) method in the orthogonal machining simulation of 1.4837D casted steel material. Furthermore, a study was conducted to understand how different SPG parameters affect simulation results, particularly force components, chip form and temperature. In the end, a Design of Experiment (DoE) was created to study the effects of cutting velocity, feed, and rake angle on force components. The simulation results were experimentally validated, and a good agreement (for cutting forces mean deviation 0–11% and feed forces 4–15%) was found between experimental and simulation results.