Modeling Grinding Processes—Mesh or Mesh-Free Methods, 2D or 3D Approach?

The objectives of this study are mainly two: (1) to validate whether a single grain scratch process can be modeled in two dimensions under the assumption plane strain, and (2) select best discretization approach model process. This paper first focuses on simulation orthogonal cutting (aluminum alloy A2024 T351) using mesh-based approaches, pure Lagrangian method (LAG) arbitrary Lagrangian–Eulerian (ALE), particle-based particle finite element (PFEM) smooth hydrodynamics (SPH), for both positive negative rake angles. Benchmarking models at angle γ=20∘ is performed with results forces (cutting passive forces) turning experiment from literature. It shown that all able predict forces, but not force. further extended simulate mechanism tool geometries typically found grinding grit scratching processes. effects angles approaches studied. calculated also compared measurements our laboratory. 2D significantly overestimate forces. One reasons why inadequate it cannot describe complex mechanisms material removal such as rubbing, plowing, cutting. To account these phenomena LAG, ALE, SPH 3D developed. When comparing experimental measurements, three show good agreement. However, seen ALE most closely matches results. Finally, was subjected sensitivity analysis by changing speed, depth cut geometry. clearly only predicts form trends observed experiments, topography satisfactorily. Hence, we conclude necessary method.