Metal cutting simulations using smoothed particle hydrodynamics on the GPU

In this work, orthogonal metal cutting simulations of Ti6Al4V are presented for two purposes: the accurate prediction of chip shapes and the automatic optimization of cutting parameters. To achieve these results, a new software tool is presented. This software tool employs meshless methods instead of the established FEM and is parallelized using GPGPU computing. These characteristics allow for a dramatic reduction in the computation time compared to established tools, enabling low-resolution simulations in the orders of minutes, and extremely high-resolution simulations in over night time frames, making the aforementioned goals possible. On the other hand, overnight simulations with very high particle numbers are conducted to study the chip shape. In the interest of reproducibility, the software tool developed is made open source and can be obtained from https://github.com/mroethli/mfree_iwf-ul_cut_gpu.