Simulation of single grain cutting using SPH method

So-called Engineered Grinding Tools (EGT) have been developed in order to satisfy the industry's demand for more efficient and cost-effective grinding tools, which differ from classic grinding tools by placing and brazing single abrasive grains in a predefined pattern onto the grinding tool body. Single grain cutting simulations form an important part towards an advanced understanding of the engineered grinding process. Cutting simulations with FE Methods encounter problems arising from large deformation and material separation. These can be overcome using meshless methods. In this work, a Smooth Particle Hydrodynamics (SPH) Method is used to model the single diamond grain cutting, which can be used as the basis process for physical simulation of the grinding process. As results the influence of the grain geometry, grain orientation and grain placement on the cutting forces, the burr generation and the chip removal rate are presented. It is shown that the cutting forces for a given grain geometry as well as the burr generation are heavily influenced by the orientation of the minor and the main cutting faces. Also cutting in material being work hardened by preceding grains, is simulated in order to be able to synthesize the grinding process from single grain cutting.