LAUSR

Abstract In the last decades, mesh-free methods for simulating various cutting processes have been used very widely as they can effectively avoid mesh distortion when dealing with large deformation problems. The current work aims to systematically study conventional and surface defect machining (SDM) using state-of-the-art smoothed particle hydrodynamics (SPH) method. The orthogonal cutting experiments were performed to evaluate the validity of the SPH simulation model. A good agreement between experimental and numerical results was achieved, which indicates that SPH method is capable of predicting the cutting forces and chip morphology correctly. The mechanisms of chip formation were investigated. Significant changes were observed in chip morphology with the variations in the cutting depths. Based on the validated numerical models, an assessment of the SDM technique was carried out using SPH method. Compared with conventional machining, SDM technique provided favourable machining results including reduced cutting forces and reductions in overall temperature in the cutting zone.