Finite Element Simulation Of High-speed Milling Process Of Metal

High-speed milling, as the main application form of high-speed cutting has been widely used in the production practice. The developed industry countries are in the forefront of walk of the world in high-speed cutting domain both in research and application, while China is still in the primary stage of development and application. As an advanced manufacturing technology, it has broad utility prospects.It takes much times and efforts to study high-speed milling process solely by experimental methods, with increased costs, and, the temperature, stress, milling forces which acquired during cutting process were affected by experimental condition. With the rapid development of the computer hardware and software technology, finite element method (FEM) has become an effective tool for the simulation of metal-cutting process.Based on high-speed machining mechanism and some key high-speed cutting simulation technologies, Johnson-Cook plasticity model was adopted as workpiece material constitutive model. Shear failure criterion and adaptive remeshing were used for separation of chips from workpiece. J-C fracture model was adopted as chip fracture model. Modified Coulomb friction law was used to define the interaction between tool rake face and chip. The effective simplification of two-dimensional high-speed milling in steel 45 was achieved in ABAQUS, and then three-dimensional high-speed milling model was established, including four oblique-angle cutting model, such as:constant cutting depth with single edge, constant cutting depth with double edge, variable cutting depth wtih single edge, variable cutting depth with double edge. End mill cutting model was established finally.Chip formation in high-speed milling of 45 steel was discussed with two-dimensional model established, which was verifed by experiments. The simulation results showed that continuous chips and discontinuous chips were formed under different cutting speed under condition of high-speed milling of 45 steel. The law of milling parameters on cutting forces and cutting temperature and stress in different chip formation were investigated. Material constitutive model, which was based on rigidity was chosen to represent finite element model, serrated chips was achieved in two-dimensional simulation of high-speed hard cutting, simulation analysis was carried out on serrated chips formation.The law of inclination angle and rake angle on cutting force and cutting temperature was discussed in three-dimensional high-speed milling simulation. It provided theoretical direction on tool designing. Multi-factor combination method was used to simulate several groups of different milling parameters, to study the effects of milling parameters on cutting forces. Finally, the range of cutting speed was summarized when low and stability milling forces were appeared in high-speed milling of 45 steel.Through the milling experiment, the collected data and simulated milling force data were compared to veriFf the finite element model being reasonable.