Comparison of Coupled Eulerian–Lagrangian and Coupled Smoothed Particle Hydrodynamics–Lagrangian in Fluid–Structure Interaction Applied to Metal Cutting

The aim of this work is to investigate a fluid–structure interaction problem, in which the chip formation and the fluid flow are coupled. Two simulation methods are developed in the commercial finite-element code ABAQUS/Explicit: the coupled Smoothed Particle Hydrodynamics–Lagrangian (SPH-L) approach and the coupled Eulerian–Lagrangian (CEL) approach. The models combine the Lagrangian approach to model the structure and the SPH/Eulerian approach to model the fluid. The simulation results are compared to analyze the advantages and limitations of the two simulation methods. The mechanical and thermal effects induced by the coolant are investigated apart. A proper user subroutine is developed to apply the heat transfer by convection induced by the fluid. The validation of the proposed models is carried out by comparing the predicted results with the experimental evidence. In general, both models show a great capability of modeling the cutting process. The percentage error between the experimental and predicted cutting forces and chip geometry is lower than 5% and 30%, respectively. The required CPU time to simulate 1.8 ms real-time simulation is 5 h 8 min with the CEL approach and 6 h 48 min with the coupled SPH-L approach. It is also found that the temperature distribution along the tool rake face is significantly decreased by up to 310 °C under the CEL approach and by up to 230 °C under the coupled SPH-L approach. However, the temperature at the tool tip recorded under both techniques is not affected and keeps a near constant value around 720 °C.