Research On High Speed Machining Using FEM Simulation Approach

High speed machining (HSM) is well appreciated and widely used in industry for modern manufacturing, and has been rapidly developing, due to its high removal rates, high precision and excellent surface finish.In the metal cutting process, there are three most important indicators:cutting force, cutting temperature and tool wear. Especially, cutting forces are widely used in this process. It directly determines the generation of heat and plays a serious role in tool wear and life, precision of work piece, quality of cut surface and so on. Besides, metal cutting process is a complex nonlinear large deformation strain rate and coupled thermal-mechanical process, so it is difficult to use the traditional method of cutting mechanism to quantitative analyze. Modeling and simulation with FEM have the potential for improving cutting tool designs and selecting optimum conditions. Finite element method is becoming one of effective method to research and simulate the cutting processes.In this paper, it is simulated AISI4340 steel machined by nano-gradient tool. Johnson-Cook constitutive model and fracture criterion which fits large deformation and strain rate analysis are used. After compared two common tool wear models, USUI model is built for the process, then commercial CAE software ABAQUS/EXPLICIT and DEFORM2D are used to establish the two-dimensional cutting model and simulate the chip formation process. Through comparative studies of simulation and theory, changing regularity between the cutting force, temperature and tool wear and the variation of the cutting parameters are obtained; In addition, for the characteristics of milling process,3D end and ball end milling models of TC4 (Ti-6A1-4V) alloy and H13 steel are established, then simulated in CAE software DEFORM3D. Custom material of Johnson-Cook model and Normalized C & L fracture criterion are used to simulate the process of chip production, and then compare with the actual stress and temperature field in milling experiment, it shows that the simulation and experiment results match well. So the milling process can be well simulated by DEFORM3D, which can provide the basis for determining optimal cutting parameters.