Finite Element Analysis And Experiments Of Cutting Force For High Speed End Milling

High-speed machining (HSM) technology, with high cutting velocity, high feed rate and perfect surface quality, is one of the most advanced technologies developed promptly in the last 20 years. HSM is the direction of advanced manufacturing technologies, and is one of the domains that have been studied most in the science and technology and industry fields. Cutting force is the basis to calculate cutting twist moment and power, and it is essential to analyze cutting heat and temperature hoist, and to study machining precision and surface quality of products. With the rapid development of computer technology, the numerical simulation method has become an important instrument.Due to the complexity in HSM process, using only one method to study cutting force is not enough. Accordingly, on the basis of metal cutting theory and elastic-plastic mechanics, FEM is used to analyze the stress-strain relation in cutting zone, and to discuss the influences of various cutting parameters on cutting force.At first, according to the characteristic of HSM, orthogonal cutting model is established, and formation mechanism of cutting zone, forces that chip suffered, friction characteristic of cutter/workpiece area, and shear angle are analyzed. Establish finite element model, and use elastic- plastic mechanics to discuss stress-stain state of elastic and plastic deformation in cutting zone. Pay attention to the material model, meshing, boundary condition, and chip separation criterion of the model, which can affect calculation precision directly. In simulation, the influence of rake angle, cutting speed, feed rate, and cutting thickness on cutting force are discussed. At last, high speed milling experiments are conducted. One-factor experiments are adopted to validate the finite element model and multi-factor orthogonal experiments are designed to validate the influence of cutting conditions on cutting force.