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Article

Comparison of Machining Simulations of Aerospace Alloy Al6061-T6 Using Lagrangian and Smoothed Particle Hydrodynamics Techniques

by
Muhammad N. Nawaz
1,
Sohaib Z. Khan
2,*,
Muhammad Asif
3,
Abdulrahman Aljabri
2,
Asad A. Zaidi
4 and
Essam R. I. Mahmoud
2
1
Department of Naval Architecture, PNEC, National University of Sciences and Technology, Karachi 75350, Pakistan
2
Department of Mechanical Engineering, Faculty of Engineering, Islamic University of Madinah, Madinah 42351, Saudi Arabia
3
Department of Engineering Sciences, PNEC, National University of Sciences and Technology, Karachi 75350, Pakistan
4
Department of Mechanical Engineering, Hamdard University, Karachi 74600, Pakistan
*
Author to whom correspondence should be addressed.
Lubricants 2022, 10(11), 310; https://doi.org/10.3390/lubricants10110310
Submission received: 21 September 2022 / Revised: 23 October 2022 / Accepted: 31 October 2022 / Published: 15 November 2022
(This article belongs to the Special Issue Friction Stir Processing of Structural Metallic Materials)
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Abstract

This research focuses on the study of the simulation capabilities of the lagrangian (LAG) model and Smoothed Particle Hydrodynamics (SPH) model for the orthogonal dry machining of aluminum alloy Al6061-T6. A three-dimensional finite element model was developed and verified using experimental data from the published literature. The numerical models were developed using lagrangian boundary conditions via finite element modeling in ABAQUS/Explicit 6.14. The cutting simulations were carried out at low and medium cutting speeds. Johnson–Cook material constitutive law and Johnson–Cook damage law were used in both models. The numerical methodologies are compared based on cutting forces, chip morphology, shear angle, chip separation criterion, and chip thickness. The findings of the present work show that the LAG model is good for predictions regarding cutting forces and chip morphology, while the SPH model is good for predictions regarding the shear angle and chip thickness. The difference between results generated by both models mainly occurred due to the friction coefficient. The comparative study shown here offers a guidance approach for various numerical models for appropriate parameter analysis.
Keywords: machining simulation; aluminum alloy 6061; lagrangian technique; SPH technique; cutting forces; shear angle; chip thickness machining simulation; aluminum alloy 6061; lagrangian technique; SPH technique; cutting forces; shear angle; chip thickness

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MDPI and ACS Style

Nawaz, M.N.; Khan, S.Z.; Asif, M.; Aljabri, A.; Zaidi, A.A.; Mahmoud, E.R.I. Comparison of Machining Simulations of Aerospace Alloy Al6061-T6 Using Lagrangian and Smoothed Particle Hydrodynamics Techniques. Lubricants 2022, 10, 310. https://doi.org/10.3390/lubricants10110310

AMA Style

Nawaz MN, Khan SZ, Asif M, Aljabri A, Zaidi AA, Mahmoud ERI. Comparison of Machining Simulations of Aerospace Alloy Al6061-T6 Using Lagrangian and Smoothed Particle Hydrodynamics Techniques. Lubricants. 2022; 10(11):310. https://doi.org/10.3390/lubricants10110310

Chicago/Turabian Style

Nawaz, Muhammad N., Sohaib Z. Khan, Muhammad Asif, Abdulrahman Aljabri, Asad A. Zaidi, and Essam R. I. Mahmoud. 2022. "Comparison of Machining Simulations of Aerospace Alloy Al6061-T6 Using Lagrangian and Smoothed Particle Hydrodynamics Techniques" Lubricants 10, no. 11: 310. https://doi.org/10.3390/lubricants10110310

APA Style

Nawaz, M. N., Khan, S. Z., Asif, M., Aljabri, A., Zaidi, A. A., & Mahmoud, E. R. I. (2022). Comparison of Machining Simulations of Aerospace Alloy Al6061-T6 Using Lagrangian and Smoothed Particle Hydrodynamics Techniques. Lubricants, 10(11), 310. https://doi.org/10.3390/lubricants10110310

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