Process simulation using finite element method -: prediction of cutting forces, tool stresses and temperatures in high-speed flat end milling
Process simulation using finite element method -: prediction of cutting forces, tool stresses and temperatures in high-speed flat end milling
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DOI：
10.1016/s0890-6955(99)00080-2
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发表时间：
2000-04-01
影响因子：
14
通讯作者：
Altan, T
中科院分区：
文献类型：
--
作者：
Özel, T;Altan, T
模具钢的端铣是一项高要求的操作，因为工件硬度高会在刀具上产生温度和应力。切削过程的建模和仿真具有改进刀具设计和选择最佳条件的潜力，特别是在高速铣削等高级应用中。本研究的主要目的是开发一种方法来模拟切削过程中的平端铣削操作和预测芯片流，切削力，刀具应力和温度，使用有限元分析（FEA）。作为一个应用，加工P-20模具钢在30 HRC硬度使用未涂层硬质合金刀具进行了研究。使用商业上可获得的软件DEFORM-2D（TM），使用先前开发的工件材料的流动应力数据和在高变形速率和温度下切屑-刀具接触处的摩擦。通过利用平面应变和轴对称工件变形模型，以预测切屑形成的平面端铣刀片的主要和次要切削刃的未变形的芯片的几何形状的模块化表示。干式加工实验槽铣削进行了使用单刀片平头米尔斯铣刀与直切削刃（即零螺旋角）。预测的切削力与实测力的比较显示出合理的一致性，并表明刀具应力和温度也预测可接受的精度。最高的刀具温度预测在主切削刃的平立铣刀刀片，无论切削条件。这些温度增加了主切削刃处的磨损发展。然而，最高的刀具应力预测在第二（圆角半径）切削刃。(C)2000爱思唯尔科技有限公司版权所有。
End milling of die/mold steels is a highly demanding operation because of the temperatures and stresses generated on the cutting tool due to high workpiece hardness. Modeling and simulation of cutting processes have the potential for improving cutting tool designs and selecting optimum conditions, especially in advanced applications such as high-speed milling. The main objective of this study was to develop a methodology for simulating the cutting process in flat end milling operation and predicting chip flow, cutting forces, tool stresses and temperatures using finite element analysis (FEA). As an application, machining of P-20 mold steel at 30 HRC hardness using uncoated carbide tooling was investigated. Using the commercially available software DEFORM-2D(TM), previously developed flow stress data of the workpiece material and friction at the chip-tool contact at high deformation rates and temperatures were used. A modular representation of undeformed chip geometry was used by utilizing plane strain and axisymmetric workpiece deformation models in order to predict chip formation at the primary and secondary cutting edges of the flat end milling insert. Dry machining experiments for slot milling were conducted using single insert flat end mills with a straight cutting edge (i.e. null helix angle). Comparisons of predicted cutting forces with the measured forces showed reasonable agreement and indicate that the tool stresses and temperatures are also predicted with acceptable accuracy. The highest tool temperatures were predicted at the primary cutting edge of the flat end mill insert regardless of cutting conditions. These temperatures increase wear development at the primary cutting edge. However, the highest tool stresses were predicted at the secondary (around corner radius) cutting edge. (C) 2000 Elsevier Science Ltd. All rights reserved.