Modeling and Simulation on Ultra-precision Cutting of Mold Steel

A Lagrangian smoothed particle hydrodynamics (SPH)-based model is carried out to simulate ultra-precision cutting of mold steel. SPH is a meshless method, thus large material distortions that occur in the cutting problem are easily managed and SPH contact control permits a "natural'' separation between workpiece and chip. Minimum cutting thickness, cutting force and heated diffusion with various cutting parameters are studied. The results of the numerical simulation demonstrate that the SPH cutting model can correctly estimate the cutting forces and attain the minimum cutting thickness in certain cases, as illustrated in some orthogonal cutting examples. Heat diffusion varies with the rake angle change. While the rake angle increases, more heat is easily diffused in addition to the too large rake angle. The developing approach is compared to experimental data and a new measure method is discussed.