Prediction of Milling Force Based on Numerical Simulation of Oblique Cutting

Abstract

This article presents a method to obtain the cutting force coefficients needed to predict the milling force using a mechanistic model of the milling process. A finite element model is developed and used to simulate the oblique cutting process of cutting edge discrete element for the Al6061-T6 milling. The model reflects the effects of high temperature, large strain, and strain rate to the workpiece material. Based on the simulation results, the relationship between cutting force coefficients and chip thickness is deduced, and inverse proportion models are presented. To validate the accuracy of the model, instantaneous milling force is predicted and shown to match the real measured force with satisfactory accuracy. Based on predicted milling force, the machining processing is optimized.