Orthogonal Variable Thickness Cutting Modeling of Surface Milling and Physical Fields Simulation

Abstract

When milling the complex surface with the ball-end milling cutter, the cutting thickness always changes in ball-end milling process. At present, many milling models are actually simplified with unchanged cutting thickness, which ignores the ball-end milling cutting with complex tool-work piece relationship. According to the characteristics of the ball-end milling, orthogonal variable thickness cutting model is established based on the study of three-dimensional contact relationship of tool-work piece. The simulation of the stress field and the temperature field in hardened steel Cr12MoV orthogonal variable thickness cutting process is conducted, and comparative analysis of stress and temperature field distribution of high-speed milling and conventional milling is made. The cutting model of orthogonal variable thickness cutting can reflect the characteristics of surface milling accurately, which can be further used in the study of changing characteristics of physical fields and the optimization of cutting and tool parameters to improve the machining efficiency and quality.