A Smoothed-Particle Hydrodynamics (SPH) Model for Machining of 1100 Aluminum

The smoothed-particle hydrodynamics (SPH) technique was used to model experimentally observed large deformation behaviour of aluminum (1100 Al) during machining. The effectiveness of the SPH method in predicting the response of the 1100 Al workpiece during orthogonal machining has been assessed through a careful comparison with the experimentally measured stress/strain distribution within the chips formed during steady state cutting. An Eulerian numerical model, previously validated for machining of copper, was also used to evaluate the SPH model. Both the Eulerian and SPH models showed good overall correlation with the experimentally measured stress/strain distribution when an exponential stress-strain behaviour was utilized in modeling. The maximum predicted plastic strains utilizing an Eulerian and SPH solution approach were 7.5 and 8.0, respectively. When the CPU time requirements were considered, the SPH model was the suitable choice to model deformation processes during cutting with relatively good accuracy and approximately 2.75 times less cost compared to the Eulerian model.