A force-temperature model including a constitutive law for Dry High Speed Milling of aluminium alloys

Abstract

In this study, a new analytical cutting force model was developed for the Dry High Speed Milling of aluminium alloys. The proposed model requires only work-material properties and cutting conditions to estimate the cutting forces and the temperature during end-milling processes. The transformation from orthogonal-to-oblique cutting was used to study the end-milling operation. A new method, which includes a Needleman-Lemonds constitutive equation, was introduced to simultaneously determine the average shear stress and the cutting temperature in the primary and secondary shear zones. The model validation was performed by comparing the prediction for machining Al6061-T6 and Al7075-T6 aluminium to mechanistic model results and experimental results. The computed temperature results were compared to published data. A good agreement was observed for both force and temperature results, for the investigated cutting conditions.