A numerical cutting model for brittle materials using smooth particle hydrodynamics

Abstract

Numerical studies on the cutting process of brittle materials have not previously been conducted, due to the difficulties involved, which stem from the differences to their fracture mechanisms compared to those of ductile materials. The purpose of this study is to propose and implement a numerical cutting model that is able to represent the removal mechanism in brittle material. For this purpose, cutting behavior was simulated using the smooth particle hydrodynamics (SPH) method and the Johnson-Holmquist material model. The numerical cutting model of brittle materials proposed here was able to realize the propagation of cracks and the formation of discontinuous chips that are cutting characteristics in brittle materials. Location data was analyzed to judge the status of surface roughness after the numerical cutting process was analyzed. Numerical analysis was conducted to find optimal cutting conditions by investigating the surface roughnesses resulting from changes to various factors (cutting speed, cutting depth, rake angle). Finally, using the optimal cutting conditions found (high cutting speed, low cutting depth, and a rake angle close to 0A degrees) was shown to contribute to improved surface roughness.