SPG Simulation of Free Orthogonal Cutting for Cutting Forces Prediction

Metal processing by cutting is a common process. The accuracy and quality of a machined part essentially depend on cutting forces and mechanics of the cutting process. Along with experimental measurements, there are many numerical techniques for cutting forces prediction. The purpose of this paper is evaluating of the Smoothed Particle Galerkin (SPG) method for modeling metal cutting and cutting forces prediction. SPG is a relatively new mesh-free method, and severe material deformations arising in the cutting process can be treated in such a way that mesh distortion is of minor effect. The SPG method leads to no element deletion, and material failure and chip formation are controlled by phenomenological failure criteria. A proposed SPG model was verified and showed a good similarity in modeling chip formation and more correct estimating the chip shape comparing with SPH as illustrated in some orthogonal cutting examples. The chip shape and cutting forces predicted values obtained with the help of this method were compared to SPH. The aim of the proposed approach is reducing high-cost experimental work or at least its amount.