Numerical simulation and analysis for metal cutting processes based on FEM and SPH

By using the coupling method of FEM and SPH, constitutive behavior of material in the metal cutting process was simulated and cutting mechanisms were analyzed. The simulation results show that the cutting process is a plastic deformation process in which cutting layer material produces shearing slip due to the extrusion of cutting tool; the extrusion and friction from cutting edge result in cold plastic deformation of material in formed surface layer, and form residual stress; the cutting force increases rapidly and then decreases, eventually varies in a certain range; the maximal effective stress varies at a certain distance to the cutting edge in stable cutting stage.