The Numerical Analysis of Cutting Forces in High Feed Face Milling, Assuming the Milling Tool Geometry

Abstract

This paper presents the research study of cutting forces assuming the geometry of the milling cutter. The particularity of the milling process is the discontinuity of chip removal assuming the chip cross-section as well as the complexity of milling tool geometry. Usually, the simplification of milling tool (or other multi-edge cutting tools) and kinematics are considered for the purpose of defining the output parameters of cutting process. However, the simplification of complex cutting tools to single-edge tool is not that informative and understandable or limited to the definition of output parameters, considering the really physical milling process. For this purpose, the paper focuses on the definition of cutting forces considering the geometry of the milling cutter. Three main geometries for face milling are known, and they are called double negative, double positive and positive/negative. Considering these geometries, the 3D different milling cutters were composed. Smooth Particles Hydrodynamics (SPH) numerical method was used to perform the simulation of full (without geometry and kinematics simplification) face milling. SPH method is the effective numerical technique to solve the problems of high deformation. For high impact deformation problem, the elastic-plastic material model with kinematic isotropic hardening was chosen. Finally, the results of calculated cutting forces are presented for face milling assuming double negative, double positive and negative/positive face milling.