Replacing friction model with interaction between particles in analyzing orthogonal and rotational cutting processes using SPH method

Document Type : Research Paper


Department of mechanical Engineering, Yazd University, Yazd, Iran


The cutting tool and work-piece of cutting process are commonly analyzed using Finite Element (FE) and Smooth-Particle Hydrodynamics (SPH) methods respectively. This is identified a compound method in this research. The interaction between cutting tool elements and work-piece particles are modeled as pressure and friction force. The coefficient of friction (CF) between cutting tool and work-piece is the fundamental parameter of friction model. The CF effects on chip morphology and cutting force. In present study, both cutting tool and work-piece of cutting process are analyzed using SPH method without Friction and pressure model (SPH.NO.F). Therefore the pressure and friction force between elements and particles in compound method are replaced with the interaction between particles. The friction in the cutting zones is a physical process that accompanies the cutting but this is not modeled in analyzing of this process, because the cutting tool and work-piece particles interact with each other using the mass and momentum conservation equation. The results of orthogonal cutting process show the chip morphology of SPH.NO.F method is the same as compound method with friction model by CF=0 and 0.17. The cutting force of SPH.NO.F method is coincided to experimental results. The cutting force of milling process is investigated using SPH.NO.F and compound method by CF=0 and 0.17.


[1]          Zhang C, Lu J, Zhang F, Ikramullah S. 2017. Identification of a new friction model at tool-chip interface in dry orthogonal cutting. Int J Adv Manuf Technol 89:921–932.
[2]          Cakir E, Ozlu E, Bakkal M, Budak E. 2018. Investigation of temperature distribution in orthogonal cutting through dual-zone contact model on the rake face. Int J Adv Manuf Technol 96:81–89.
[3]          Asad M, Girardin F, Mabrouki T, Rigal J-F. 2008. Dry cutting study of an aluminium alloy (A2024-T351): a numerical and experimental approach. Int J Mater Form 1:499–502.
[4]          Calamaz M, Coupard D, Ã FG. 2008. A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti – 6Al – 4V. Int J Mach Tools Manuf 48:275–288.
[5]          Maranhão C, Davim JP. 2010. Simulation Modelling Practice and Theory Finite element modelling of machining of AISI 316 steel : Numerical simulation and experimental validation. Simul Model Pract Theory 18:139–156.
[6]          Monaghan JJ. 1992. Smoothed Particle Hydrodynamics. Annu Rev Astron Astro-physics 30:543–574.
[7]          Benz W, Asphaug E. 1995. Simulations of brittle solids using smooth particle hydrodynamics. Comput Phys Commun 87:253–265.
[8]          Monaghan JJ. 2012. Smoothed Particle Hydrodynamics and Its Diverse Applications. Annu Rev Fluid Mech 44:323–346.
[9]          Randles P, Libersky LD. 1996. Smoothed particle hydrodynamics: some recent improvements and applications. Comput methods Appl Mech 139:375–408.
[10]        Cleary PW, Das R. 2008. The Potential for SPH Modelling of Solid Deformation and Fracture. In: IUTAM Symp. Theor. Comput. Model. Asp. Inelast. Media. pp 287–296.
[11]        Gray JP, Monaghan JJ, Swift RP. 2001. SPH elastic dynamics. Comput Methods Ap-plied Mech Eng 190:6641–6662.
[12]        Hiermaier S, Konke D, Stilp AJJ, Thoma K, Könke D. 1997. Computational simulation of the hypervelocity impact of al-spheres on thin plates of different materials. Int J Impact Eng 20:363–374.
[13]        Takabi B, Tajdari M, Tai BL. 2017. Numerical study of smoothed particle hydrodynamics method in orthogonal cutting simulations – Effects of damage criteria and particle density. J Manuf Process 30:523–531.
[14]        Geng X, Dou W, Deng J, Ji F, Yue Z. 2017. Simulation of the orthogonal cutting of OFHC copper based on the smoothed particle hydrodynamics method. Int J Adv Manuf Technol 91:265–272.
[15]        2007. LS-DYNA Keyword User’s Manual. .
[16]        Nam J, Kim T, Cho SW. 2016. A numerical cutting model for brittle materials using smooth particle hydrodynamics. Int J Adv Manuf Technol 82:133–141.
[17]        Avachat CS, Carolina N, Carolina N. 2015. A Parametric Study of the Modeling of Orthogonal Machining. In: Proc. ASME 2015 Int. Mech. Eng. Congr. Expo. pp 1–10.
[18]        Xi Y, Bermingham M, Wang G, Dargusch M. 2014. SPH / FE modeling of cutting force and chip formation during thermally assisted machining of Ti6Al4V alloy. Comput Mater Sci 84:188–197.
[19]        Calamaz M, Limido J, Nouari M, Espinosa C, Coupard D, Salaün M, Girot F, Chieragatti R. 2009. Int . Journal of Refractory Metals & Hard Materials Toward a better understanding of tool wear effect through a comparison between experiments and SPH numerical modelling of machining hard materials. Int J Refract Met Hard Mater 27:595–604.
[20]        Niu W, Mo R, Liu GR, Sun H, Dong X. 2018. Modeling of orthogonal cutting process of A2024-T351 with an improved SPH method. Int J Adv Manuf Technol 95:905–919.
[21]        Spreng F, Eberhard P. 2018. Modeling of Orthogonal Metal Cutting Using Adaptive Smoothed Particle Hydrodynamics. In: Biermann D., Hollmann F. (eds) Thermal Effects in Complex Machining Processes. Lecture Notes in Production Engineering. Springer, Cham. pp 133–143.
[22]        Müller M, Schirm S, Teschner M, Heidelberger B, Gross M. 2004. Interaction of fl uids with deformable solids. J Vis Comput Animat 15:159–171.
[23]        Umer U, Mohammed MK, Qudeiri JA. 2016. Assessment of finite element and smoothed particles hydrodynamics methods for modeling serrated chip formation in hardened steel. Adv Mech Eng 8:1–11.
[24]        Vila JP. 2006. SPH renormalized hybrid methods for conservation laws: applications to free surface flows. In: Meshfree Methods Partial Differ. Equations II. Lecture Notes in Computational Science and Engineering, pp 207 – 229.
[25]        Liu GR, Liu MB. 2003. Smooth Particle Hydrodynamics : a mesh free particle method . World Scientific, 5 Toh Tuck Link, Singapore 596224, ISBN 9789812384560.
[26]        Madaj M, Píška M. 2013. On the SPH orthogonal cutting simulation of A2024-T351 alloy. Procedia CIRP 8:152–157.
Volume 52, Issue 2
June 2021
Pages 297-306
  • Receive Date: 01 May 2019
  • Revise Date: 07 August 2019
  • Accept Date: 20 August 2019