Authors:Â A. Sreenivasa Rao, K Venkata Rao
Abstract:Â Finite element simulations have been utilized in analyses of machining process for several decades. This paper presents the development of a cutting force model for end milling process under various cutting conditions and the tool wear is measured by Scanning Electron Microscope (SEM).This novel approach combines the concept of experimental design and finite element modeling of the cutting process which allows for a fairly accurate prediction of cutting forces with a significantly lower computational cost. The simulated results are compared against the experimental observations. The results have shown that the material AISI 316 Stainless steel has affects on cutting forces and tool wear. In cutting approach, Deform 3Dv6.1 software is used to simulate the milling process. The simulation and experimentation is performed based on Taguchi design of experiments. In this research, three dimensional finite element modeling and simulation issues for vibration assisted milling are explored in detail. Machine dynamic effects are taken into account to predict the outcomes such as tool wear and cutting forces. The model can be implemented in an online tool wear monitoring system which predicts the actual state of tool wear in real time by correlating cutting force variations during machining. The comparisons of simulations with experimental results demonstrate their predictive capability. From the results, useful conclusions may be drawn, and it can be stated that the proposed models can be used for industrial application.
Keywords: End milling, Cutting force, Tool Wear, Machining, Metal cutting, Modeling.
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