Prediction of Cutting Forces during End Milling using 3D FEM based Simulation Analysis

Abstract

Material removal process for dies, moulds and additionally diverse aircraft parts can be made possible by the highspeed end milling operation. Devious cutting forces are created by the impact of various cutting parameters in course with high speed milling process. Due to this phenomenon the wear and chatter of tool can occur. Cutting force prediction is useful method to reduce the chatter occurrence during the machining of hardest materials. DEFORM 3D is an important simulation software which is used for the analysis of complicated metal removal processes. In this work, the tool insert was designed by Solid Works modelling software. The FEM simulation of high-speed end milling of Titanium-Vanadium based alloy was carried out in Deform 3D simulation software to obtain the cutting forces. The material behaviour was modelled with a classical constitutive material equation and was applied in the FEM code to predict the effective stress, strain, temperature and cutting forces towards the impact of cutting parameters. Analysis of variance is achieved to determine the impact of cutting forces with help of Taguchi method in Minitab-17. L16 orthogonal array was used to conduct the analysis of high speed end milling.