CUTTING FORCES, CHIP FORMATION AND TEMPERATURE FOR TWO-DIMENSIONAL FINITE ELEMENT SIMULATION OF MILLING PROCESS

Milling is a key machining technology for manufacturing. The correct design of the cutting conditions, together with the appropriate geometry of the cutting tool, can contribute to greater productivity in the milling process. In this study, a two-dimensional finite element (FEM) simulation of the milling process was used to compare the cutting forces obtained by simulation with milling experiments and dynamometer measurements. The results showed that the FEM simulation was able to provide a simplified representation of the complex three-dimensional process, but it provides a clear picture of key phenomena such as stress distribution, temperature evolution, chip formation, and cutting forces. The STFC company DEFORM software is used for the FEM simulation model.