Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-milling of Al6061-T6. Finite element (FE) simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects of mill helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.

3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of aluminum 6061-T6

DAVOUDINEJAD, ALI;PARENTI, PAOLO;ANNONI, MASSIMILIANO PIETRO GIOVANNI
2017

Abstract

Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-milling of Al6061-T6. Finite element (FE) simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects of mill helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.
3D finite element modeling; burr formation; chip formation; cutting force; micro endmilling; Mechanical Engineering
File in questo prodotto:
File Dimensione Formato  
3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of aluminum 6061-T6.pdf

Accesso riservato

: Publisher’s version
Dimensione 879.69 kB
Formato Adobe PDF
879.69 kB Adobe PDF   Visualizza/Apri
03D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of aluminum 6061-T6.pdf

accesso aperto

: Post-Print (DRAFT o Author’s Accepted Manuscript-AAM)
Dimensione 6.95 MB
Formato Adobe PDF
6.95 MB Adobe PDF Visualizza/Apri

I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.

Utilizza questo identificativo per citare o creare un link a questo documento: http://hdl.handle.net/11311/1023875
Citazioni
  • ???jsp.display-item.citation.pmc??? ND
  • Scopus 13
  • ???jsp.display-item.citation.isi??? 8
social impact