DESIGN, MODELLING AND SIMULATION OF SIDE AND FACE MILLING CUTTER
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Date
2015-09-10
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Abstract
Traditionally, the design field has been identified with particular end products, e.g., mechanical design,
electrical design, ship design. In these fields, design work is largely based on specific techniques to
foster certain product characteristics and principles . Computer technology has touched all areas of
today’s life, impacting how we obtain railway tickets, shop online and receive medical advice from
remote location. Computer-based design analysis is nowadays a common activity in most development
projects. The scope of this work includes, to design, model and simulate side and face milling cutter,
to select cutting tool materials and also to detailed factor safety in design . When new software and
manufacturing processes are introduced, traditional empirical knowledge is unavailable and considerable
effort is required to find starting design concepts. Modeling and simulation of cutting processes have
the potential for improving cutting tool designs and selecting optimum conditions, especially in
advanced applications such as high-speed milling. Milling operation is today the most effective and
productive manufacturing method for roughing and finishing large surfaces of metallic parts.. The model
simulates precisely the tool kinematics and considers the effect of the cutting geometry on the resulting
roughness. The accuracy of the simulation model has been thoroughly verified, with the aid of a wide
variety of experiments. Metal cutting process is not only a material removal process, but also a
deformation process where deformation is highly concentrated in a small zone . Thereby, it can be
investigated as a chip formation process and simulated using Finite Element Method (FEM) techniques.
The main advantage of such an approach is to be able to predict all process variables arisen in the
deformation zones. However, material flow characteristics at the high temperature, strain-rate and strain,
encountered during cutting process, are very important for predicting chip flow, cutting forces,
temperatures and stresses.