STUDY ON BALL END MILLING PROCESS USING TWO DIMENSIONAL FINITE ELEMENT METHOD
Keywords:Finite element method (FEM), 2D orthogonal end milling, cutting force prediction, cutting temperature prediction, friction model
AbstractIn this paper, finite element analysis on laser sintered material machining with predicted cutting force and temperature distribution is explained. The process involved 2D orthogonal down-cut milling with the application of two dimension thermo mechanical plane strain model. The updated Lagrangian formulation was used whereas cutting simulation does not involved element separation but automatic remesh when element distorted critically. AISI 1055 mild steel properties were used as comparison. Various types of friction models were adopted in obtaining precise results. Predicted cutting force and cutting edge temperature are validated against corresponding experimental values by previous researches. From the simulation results, the shear friction model of 0.8 is the optimum friction model whereas 5-15% errors were obtained for increasing machining radial depth for AISI 1055. Lower cutting force predicted for laser sintered materials as compared to AISI 1055 due to lower Young modulus value. Cutting edge temperature predicted for laser sintered materials is higher due to its low thermal conductivity as compared to AISI 1055.
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