Modelling of high speed cutting using a coupled finite element (FE)-smoothed particle hydrodynamics (SPH) single-grain model

In this study, to simulate the grinding process for rolled homogeneous armor steel (RHA) 4043, a single-grain cutting process is modeled using a three-dimensional (3-D) numerical model, which is developed using a coupled finite element (FE)-smoothed-particle hydrodynamics (SPH) approach. The proposed numerical model is then employed to investigate the influences of grain negative rake angle (–22°, –31°, and –45°) as well as high and super-high cutting speed ranged from 100 m/s to 260 m/s in the cutting processes. The numerical results show the cutting forces and average height of side face of pile-ups are much lower than other sides and the maximum chip thickness is much larger when using a smaller grain negative rake angle.