Cutting Forces Evaluation in Milling using an Analytical /Finite Element Mixed Approach

Simulation of the machining process is a widespread technique to predict the optimal parameters for machining operations. The simulation of the cutting forces can be achieved by using two different techniques. The first is the use of mechanistic models based on linear analytical expression of the cutting forces and is the most common one. These models are able to compute the efforts acting on complex tools but need experi-mental tests to determine the specific parameters. The second is based on the finite element method. Finite element computations of the machining are able to predict cutting forces, chip formation, heat generation from the knowledge of the properties of the materials. The aim of this paper is to present a method to link cutting forces computed by finite element method with a local geometry to the global efforts on a complex milling tool.The finite element simulation is performed with the finite element software Morfeo (Manufac-turing ORiented Finite Element tOol). Morfeo is Cenaero's in-house code devoted to re-spond to the industry specific needs. For this paper, an updated Lagrangian description with an automatic and adaptive remeshing was used. Simulation results include predic-tion of cutting forces, which require an accurate computation of the complex phenomena on the contact interface. At the contact interface nonmatching meshes are considered and a frictional contact inducing heat generation is used. In addition, the heat transfer coefficient depends on the contact pressure. The efforts computed by Morfeo can then be used as inputs for the dynamic simulation of a complex milling process including self excited vibrations.