Using SPH-FEM Couple Method To Simulate Micro-milling Process And Micro-milling Test

Micro-cutting process simulation technology has been one of the hotspots in the field ofmicro-machining technology. In this study, the micro-milling process simulation that using PCDmicro-milling tool to mill aluminum alloy5083material was conducted based on the SPH-FEMcoupling method. As a contrast, the micro-milling experiment was carried out. The effect of front rakeangle of side edge and cutting edge radius on micro-milling force and micro-milling burr wasanalyzed. This paper is as follows:(1) On the basis of SPH-FEM couple method theoretical analysis and the characteristics of themicro-milling process, the three-dimensional micro-milling simulation model was built based onSPH-FEM couple method. And the simulation model was solved by software ANSYS/LA-DYNASOLVER.(2) Through the micro-milling simulation, when changing the front rake angle of side edge frompositive rake angle to negative rake angle, the micro-milling force showed an increasing trend.Positive rake angle tool mainly formed cut out burr, negative rake angle tool formed top burr, and theburr was more serious with the greater negative rake angle. With the increasing cutting edge radius,the micro-milling force increased. The cutting edge radius affected burr formation. With theincreasing cutting edge radius, the burr worsened steadily.(3) Micro-milling experiment results of milling aluminum alloy5083showed that the millingforce increased significantly with the increasing feed rate per tooth. The cutting edge radius had animportant impact on the micro-milling force and burr as well. With the increasing cutting edge radius,the micro-milling force increased, and micro-milling burr became worse.