Modeling High Speed Machining with the SPH Method

The purpose of this work is to evaluate the use of the Smoothed Particle Hydrodynamics (SPH) Method within the framework of modeling high speed cutting. First, a 2D SPH based model is carried out using the LS-DYNA® software. SPH is a meshless method, thus large material distortions that occur in the cutting problem are easily managed and SPH contact control allows a “natural” work piece/chip separation. The developed SPH model proves its ability to account for continuous and shear localized chip formation and also correctly estimates the cutting forces, as illustrated in some orthogonal cutting examples. Then the SPH model is used in order to improve the general understanding of machining with worn tools. At last, a milling model allowing the calculation of the 3D cutting forces is presented. The interest of the suggested approach is to be freed from classically needed machining tests: Those are replaced by 2D numerical tests using the SPH model. The developed approach proved its ability to model the 3D cutting forces in ball end milling.