Finite element simulations of the material loads and residual stresses in milling utilizing the CEL method

Abstract

Abstract Within the process chain for the production of highly stressed components, finishing is of particular importance - the resulting surface layer properties of the workpiece decisively determine the component functionality. According to the concept of Process Signatures proposed by Brinksmeier and others, in the present work the internal material loads and the resulting material modifications are analyzed for milling of quenched and tempered 42CrMo4 (AISI 4140). 3D finite element simulations were conducted utilizing the Coupled Eulerian-Lagrangian (CEL) method for which remeshing can be omitted. This is u.a. because the stresses during the process can not be measured in the required temporal and spatial resolution. Therefore, in this work, 3D finite element simulations are used to investigate the influence of repetitive stress on hard milling. The formation of stresses at variable tooth feed, but with constant cutting speed and depth of cut is investigated. The development of material modifications (residual stresses) due to multiple stresses was determined and compared with experimental results. Results from the simulation show good accuracy in comparison with the experimentally determined cutting force and active force. The use of the CEL method in the simulation of milling allows us to determine the stresses in sufficient spatial and temporal resolution without the use of remeshing