The Analysis And Study Of Milling Cutter Body's Structure

Today's demand for quality products at low cost requires a closer look at manufacturing operations. High speed machining is a relatively new production technology;milling is one of the most versatile metal cutting processes of modern time and the milling cutter body plays a great influence in the process overall efficiency. According to the related literature, the performance of the milling cutter is not yet well explored though many efforts have been done.This paper presents an analytical study on milling cutter body; two methods of milling are introduced. The major cutting tools materials, their structures and areas of application are presented; a literature of some research works in relation with the present topic is reviewed.The current research and development of high speed cutting technology in some developed countries and china are explored, the issues faced by Chinese manufacturing industry and efforts made in the area by many high academic institutions and research centers are emphasized.Three milling insert geometries have been studied and compared, three types of milling insert clamp methods and their criteria of selection are analyzed.The fundamental of finite element method procedure is outlined, a face milling force model, the expression of the maximum and average chip thickness, chip width and cutting area are established.A face milling cutter model with 7 cutting teeth is proposed to find the maximum number of teeth in simultaneous cut with their respective cutting angles; the corresponding cutting force components are computed. In the process of determining the cutting angles, two milling operation cases of different workpiece cutting width to cutter diameter ratios are proposed. In the first case, the ratio is equal to 1 while in the second case it is 2/3; these represent conditions of severe and good cutting process, respectively.The concept of contact analysis and contact classification is introduced; the contact capabilities of ANSYS are outlined.ANSYS was used to perform finite element analyses of the proposed model. Nodal solution results indicated that the cutter body, cutting insert and the screw react differently to the applied loads. It was found that, for the same loads and considering the individual component, the screw experienced the highest deformation compared to the cutting insert and cutter body. Results of the two cases compared show that, the cutting process with ratio equal to 1 experienced the highest deformation; these results are valid for both single body and assembly.Stress analysis results solely focused on the cutter body show that relatively low compression stresses apply on the cutting insert seat internal diameter peripheral edge.With regards to the above results and simulation conditions, it can be deducted first, that the values are consistent with the theoretically computed forces and second, they permitted to locate the weakest sections of each component through assessment of the individual reactions.