Investigation of high speed flat end milling process-prediction of chip formation, cutting forces, tool stresses and temperatures

End milling of tool steels is a highly demanding operation because of the temperatures and stresses generated on the cutting tool due to high workpiece hardness. Modeling and simulation of cutting processes have the potential for improving cutting tool designs and selecting optimum conditions, especially in advanced applications such as high speed milling.; The main objective of this work was to develop a methodology for simulating cutting process in flat end milling operation and predicting chip flow, cutting forces, tool stresses and temperatures using finite element analysis (FEA). As an application, machining of P20 AISI 4130 mold steel at 30 HRC hardness using uncoated carbide tooling was selected.; In order to model and simulate the cutting process using FEA, a methodology to determine flow stress of the workpiece material at high deformation rates and temperatures, and friction at the chip-tool contact was developed. The unknown parameters in workpiece flow stress and friction models were estimated using the results of process simulations for orthogonal cutting and the measurements from high speed orthogonal cutting experiments.; Two dimensional process simulation models were developed to predict chip formation and cutting forces in flat end milling process. An experimental set-up was built for slot milling operation using single insert flat end mills with a straight cutting edge (i.e. null helix angle) in order to validate simulated chip formation for milling process. A limited number of experiments were conducted on a horizontal milling center at the high speed milling conditions using the referred workpiece and tool material pair.; Predictions from the process simulations were compared with the experimental results. Comparison of predicted cutting forces with the measured forces showed reasonable agreements to validate developed process model for further use of prediction in tool stresses and temperatures.; An approximation to model the chip flow around the nose radius of the cutting tools was developed. A modular representation of undeformed chip geometry was introduced using plane strain and axisymmetric workpiece deformation models in the process simulations. A procedure for segmenting undeformed chip area into several elements to compute cutting conditions was also outlined.