A Methodology for 2D Cutting Process Simulation of Solid End Mill

The FEM simulation of end mill is complex, due to the three dimensional tool geometry. In this paper 2D FEM simulation, obtained with Thirdwave AdvantEdge v.7.0, was used in order to set up the material model. A proper machining test was designed in order to compensate the helix angle of the tool, in order to have 2D cutting forces. A mechanicistic model was developed in order to simulate, together with 2D FEM, the cutting forces in milling operation. A comparison with experimental cutting forces have been performed in order to validate the methodology.