| The technologies on microminiaturization have the world-wide practical application prospect. One of the micro/meso-machnical manufacturing technology, the micro-cutting technology which can machine any material and complex 3D product in the miniaturization machine tool equipment has attracted special attention of scholars home and abroad. However, micro-cutting is more than just a simple scaled down of macro-cutting, it has a scale effect and minimum chip thickness and so on, and these phenomena can not be explained by macro-cutting theory. So, the study for the mechanism characteristics of micro-cutting process has an important theoretical and practical application value.In this paper, based on an analysis of the current micro-cutting technology and a summary of the advantages and disadvantages of various numerical simulation method, using SPH-FEM coupling method to simulate micro-cutting process. The research work is completed as follows:(1) Analyze the basic principles of SPH method and its special implementation process in LS-DYNA, in view of the characteristics of micro-cutting proces, establish SPH-FEM based model of three-dimensional orthogonal simulation and verify the simulation results with experiment data.(2) Based on the simulation model established, simulate micro-cutting process, chip formation process and the edge radius effect on the chip morphology is analyzed, using the method of of theoretical analysis combined simulation to study minimum cutting thickness. Study the influence of cutting thickness, cutting depth, cutting speed, cutting edge radius and other factors on the micro-cutting force deeply.(3) Based on the simulation model established, conduct exploratory research in view of the characteristics of micro-surface roughness and residual stress, analyze the influence of cutting edge radius and cutting thickness on micro-surface roughness, conduct in-depth analysis of machining parameters and tool geometry on the surface residual stress.
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