3D milling modeling: mechanical actions, strains, strain rates and temperature calculations in the three cutting zones

Abstract

Analytical and semi-analytical modelling of manufacturing processes involving material removal are of great interest to scientists and industrialists. With this type of modelling, we are able to identify optimal cutting parameters based on geometric and thermomechanical quantities, without having to carry out experimental trials or costly simulations (thus saving time and reducing costs). Compared with other machining techniques, milling involves additional complexities arising from the variation in geometric parameters in the machining configuration and in kinematic parameters when operational. This paper presents a new 3D modelling analysis applied to milling, which takes into account phenomena generated by the three-dimensional kinematics of the process. To complete this thermomechanical approach to cutting, improvements have been made to a basic model configuration. The model that has been developed can now map strains, strain rates, stresses and temperatures along the cutting edge, in the primary, secondary and tertiary shear zones. Forces and cutting moments at the theoretical tool tip are estimated at a local then a global scale, and compared with experimental results from previous work.