Modeling modulated tool path turning using coupled smoothed particle hydrodynamics and finite element method

This paper describes a full-scale, three-dimensional coupled smoothed particle hydrodynamics (SPH) and finite element model for modulated tool path (MTP) turning. The chip breaking mechanism due to modulated motion of the tool is demonstrated by the developed machining model. In contrast, the simulation of conventional turning with the same machining conditions predicts long continuous chips. The cutting force predicted by the simulation is validated with a mechanistic force model based on the instantaneous chip thickness. This work expands the capabilities of machining simulations to predict complex machining phenomena such as MTP turning through a full-scale realistic simulation. The encouraging simulation results show the potential to study more complex phenomena, such as evaluating the parameters of tool path modulation, simulating ultrasonic machining, and studying machining stability.