Abstract
The work is devoted to the development of a finite element model of machining the workpiece flat surface from gray cast iron with one tooth face oblique milling cutter in the DEFORM-3D software. The model development methodology is described step by step. The preparation peculiarities of solid-state models of workpiece and cutting insert, finite-element mesh generation, as well as preprocessor setup are discussed. It is shown that to save calculation time, it is advisable to develop a 3D model of only a part of the workpiece with a cut from the path of the previous cutter insert, formed using the SolidWorks Motion module. 2 options of a finite element mesh with a different number of elements were considered. In addition, local refinement of the workpiece mesh in the area of interaction with the cutting insert was used. As a result of finite element simulation of the face milling process, the cutting forces in the feed range of 0.25…0.625 mm/tooth, with a cutting speed of 150 m/min and a cutting depth of 0.12 mm were calculated. The adequacy of the developed model is confirmed by comparison with the experimental results for the corresponding processing conditions. The finite element model of the face milling developed in DEFORM-3D will be used to further optimize the geometric parameters of the cutter to increase the efficiency of machining flat surfaces of grey cast iron parts.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Ducobu, F., Riviere, E., Filippi, E.: On the importance of the choice of the parameters of the Johnson-Cook constitutive model and their influence on the results of a Ti6Al4V orthogonal cutting model. Int. J. Mech. Sci. 122, 143–155 (2017). https://doi.org/10.1016/j.ijmecsci.2017.01.004
Zhang, Y., Outeiro, J.C., Mabrouki, T.: On the selection of Johnson-Cook constitutive model parameters for Ti-6Al-4V using three types of numerical models of orthogonal cutting. Procedia CIRP 31, 112–117 (2015). https://doi.org/10.1016/j.procir.2015.03.052
Vovk, A., Sölter, J., Karpuschewski, B.: Finite element simulations of the material loads and residual stresses in milling utilizing the CEL method. Procedia CIRP 87, 539–544 (2020). https://doi.org/10.1016/j.procir.2020.03.005
Ducobu, F., Arrazola, P.-J., Rivière-Lorphèvre, E., Ortiz de Zarate, G., Madariaga, A., Filippi, E.: The CEL method as an alternative to the current modelling approaches for Ti6Al4V orthogonal cutting simulation. In: 16th CIRP Conference on Modelling of Machining Operations (16th CIRP CMMO) Procedia CIRP, vol. 58, pp. 245–250 (2017). https://doi.org/10.1016/j.procir.2017.03.188
Dobrotvorsky, S.S., Basova, E.V., Dobrovolskaya, L.G.: Computer design and simulation of technological processes of high-speed milling of hardened steels. Bull. Lviv Polytech. Natl. Univ. 822, 1–6 (2015)
Ducobu, F., Rivière-Lorphèvre, E., Filippi, E.: Material constitutive model and chip separation criterion influence on the modeling of Ti6Al4V machining with experimental validation in strictly orthogonal cutting condition. Int. J. Mech. Sci. 107, 136–149 (2016). https://doi.org/10.1016/j.ijmecsci.2016.01.008
Borysenko, D., Karpuschewski, B., Welzel, F., Kundrák, J., Felhő, C.: Influence of cutting ratio and tool macro geometry on process characteristics and workpiece conditions in face milling. CIRP J. Manuf. Sci. Technol. 24, 1–5 (2019). https://doi.org/10.1016/j.cirpj.2018.12.003
Mehta, S., Singh, G., Saini, A., Singh, H.: Finite element analysis of face milling of Ti-6Al-4 V alloy considering cutting forces and cutting temperatures. Proceedings (2021). https://doi.org/10.1016/j.matpr.2021.10.061
Geng, G., Zhang, L., Xiao, M., Dong, X., Chen, K.: Finite element analysis and parameter optimization selection of high speed milling GH4169. In: Manufacturing Technology, vol. 20, no. 3, pp. 300–306 (2020)
Hlembotska, L., Balytska, N., Melnychuk, P., Melnyk, O.: Computer modelling power load of face mills with cylindrical rake face of inserts in machining difficult-to-cut materials. Sci. J. TNTU 93(1), 70–80 (2019). https://doi.org/10.33108/visnyk_tntu2019.01.070
Benabid, F., Benmoussa, H., Arrouf, M.: A thermal modelling to predict and control the cutting temperature. The simulation of face-milling process. Procedia Eng. 74, 37–42 (2018). https://doi.org/10.1016/j.proeng.2014.06.220
Lima, H.V., Campidelli, A.F.V., Maia, A.A.T., Abrão, A.M.: Temperature assessment when milling AISI D2 cold work die steel using tool-chip thermocouple, implanted thermocouple and finite element simulation. Appl. Therm. Eng. 143, 532–541 (2018)
Schweinoch, M., Joliet, R., Kersting, P.: Predicting thermal loading in NC milling pro-cesses. Prod. Eng. Res. Devel. 9, 179–186 (2015)
Tapoglou, N., Antoniadis, A.: 3-dimensional kinematics simulation of face milling. Meas.: J. Int. Meas. Confed. 45(6), 1396–1405 (2012). https://doi.org/10.1016/j.measurement.2012.03.026
Arizmendi, M., Jiménez, A.: Modelling and analysis of surface topography generated in face milling operations. Int. J. Mech. Sci. 163, 105061 (2019). https://doi.org/10.1016/j.ijmecsci.2019.105061
Pimenov, D.Y., Guzeev, V.I., Krolczyk, G., Mozammel Mia, S.: Modeling flatness deviation in face milling considering angular movement of the machine tool system components and tool flank wear. Precis. Eng. 54, 327–337 (2018). https://doi.org/10.1016/j.precisioneng.2018.07.001
Hlembotska, L., Melnychuk, P., Balytska, N., Melnyk, O.: Modelling the loading of the nose-free cutting edges of face mill with a spiral-stepped arrangement of inserts. Eastern-Eur. J. Enterp. Technol. 1(91), 46–54 (2018). https://doi.org/10.15587/1729-4061.2018.121712
Chernykh, D.M., Tkachenko, Y., Tsyganov, V.S.: Simulation of the machining process in order to optimize the operating parameters. Bull. Voronezh State Tech. Univ. 15(1), 130–137 (2019)
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2023 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this paper
Cite this paper
Vyhovskyi, H., Plysak, M., Balytska, N., Hlembotska, L., Otamanskyi, V. (2023). Numerical Simulation of Cutting Forces in Face Milling. In: Tonkonogyi, V., Ivanov, V., Trojanowska, J., Oborskyi, G., Pavlenko, I. (eds) Advanced Manufacturing Processes IV. InterPartner 2022. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-031-16651-8_21
Download citation
DOI: https://doi.org/10.1007/978-3-031-16651-8_21
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-031-16650-1
Online ISBN: 978-3-031-16651-8
eBook Packages: EngineeringEngineering (R0)