FEM Simulation Research On Milling Typical Profile Of Hardened Steel Mold

The rapid development of automobile industry causes a huge demand forautomobile panel mold, and both corner and surface are very common of surfacefeatures on automobile panel dies. However, the load fluctuation have adverseeffects on machine, machined surface quality and cutting tool, therefore, study oncutting load characteristics of the two type surface in machining has practicalsignificance. However, the means of experience and experiment, which arecommonly used in milling force study, are time-consuming and blindness to somedegree. Because of computer technology and finite element simulationtechnology becoming mature, simulation precision has improved gradually, andits advantages of economy and efficiency make it become an important researchmeans in study of metal cutting process.Through numerical simulation method，and combined withkey technology offinite element simulation of cutting process, such as material constitutive model,chip separation criterion，friction model, etc. a thermal-mechanical couplingthree-dimensional finite element simulation model of ball end milling hardenedsteelCr12MoV is established based on DEFORM-3D.With object movementcontrolled by tool location with milling time to realizes curve trajectory, andmesh generation technology and reasonable iterative algorithm used to ensureconvergence of simulation results, the finite element simulation for hard millingwith tool curves path is obtained.Taking right-angle corner profile and convex surface as workpiece model,three-dimensional finite element simulation models of milling right-angle cornerand milling convex surface are established. Milling force characteristics andchange rules are studied under different spindle speeds and feeds by numericalsimulation.Due to finite element simulation established under the ideal conditions, complex cutter movement, generous calculation and other reasons, simulationresults have discrepancy. Milling experiments are designed and carriedoutaccording to the characteristics of the two type profiles under correspondingcutting parameters of simulation models, and discrepancy of simulation value andexperiment measured value is analyzed. This paper realized cutting toolmovement with curve path in finite element simulation model, which provides auseful reference for realizing complex path in simulation and auxiliary supportfor developing cutting tool.