Numerical Modeling of Orthogonal Machining Process Using Smoothed Particle Hydrodynamics—A Parametric Study

Some of the challenges faced during numerical modeling of machining processes using finite element method are: extreme deformations, complicated and discontinuous contact conditions between the workpiece and cutting tool, and the chances of self-contact due to chip curling. Another difficulty encountered in FEM is in the form of mass and energy losses. Lately, the smoothed particle hydrodynamics (SPH) method has developed as a potential alternative for modeling machining processes due to its ability to handle severe deformations while avoiding energy losses and mass losses encountered by traditional FE Model. This method has been implemented in commercial finite element package Abaqus, for solving problems involving localized severe deformations. Several control parameters are used in a typical SPH formulation. The purpose of this research work is to investigate the influence of the important factors such as the type of SPH formulation, mass scaling, particle density, artificial bulk viscosity, and the smoothing length in the numerical modeling of orthogonal machining of AISI 1045 steel. The challenges involved in accurately modeling this highly nonlinear problem is handled using the Abaqus/Explicit integration scheme along with the Johnson–Cook material model. Results from this parametric study are validated with the results from previously published literatures.