The energetic characteristics of milling with changing cross-section in the definition of specific cutting force by FEM method
János Kundrák, Bernhard Karpuschewski, Zoltán Pálmai, Csaba Felhő, Tamás Makkai, Dmytro Borysenko
Abstract
With cutting technology, including milling, new tasks must constantly be solved, for which the knowledge of the cutting force is necessary from the theoretical point of view and for the practical application of the technology. This article summarizes the results of a project to study the cutting force during milling. The technological analysis of milling was performed by FEM simulation, which was validated by measuring the cutting force. When milling, only one insert was placed in the cutter, the workpiece was C45 rolled steel, which was machined with different depths of cut ap and feed rates fz while the cross section Ac = ap · fz = 0.9 mm2 was kept constant. The calculations proved that the effect of the cross-section of the material deposited during milling, and thus the specific features of the technology, is well characterized by the chip ratio ap/fz. It has been shown that from the energy point of view it is expedient to avoid the chip ratio of ap/fz = 1 in the applied technology. It is preferable to set the value as far away as possible, preferably aiming to use ap/fz < 1.