Simulation of the orthogonal cutting of OFHC copper based on the smoothed particle hydrodynamics method

In the last decades, mesh-free methods for simulating various cutting processes have been used very widely as they can eliminate numerical problems in the simulation of material failure and large plastic deformations. This paper employs smoothed particle hydrodynamics (SPH) method to simulate orthogonal cutting process. The effects of friction coefficient between tool and workpiece on the predicted cutting force and chip morphology are investigated. It is interesting to note that the cutting force decreases as the friction coefficient varies from 0.1 to 0.3. Besides, the developed SPH model gained its ability to correctly estimate the cutting forces, as illustrated in orthogonal cutting simulations. Cutting forces were compared for SPH and experimental results. The predicted cutting forces agree within 15.4 and 14.7% of the measured values for tangential and normal components, respectively. For the average chip strain, the simulation results also accord with the theoretical values well.