A Steady State Thermal Behavior Study of 3D Ball End Milling Model by Using Finite Element Method
In this paper a three-dimensional finite element model is presented to simulate the thermal behaviour of steady-state ball end milling process. In this model, the appropriate tool, chip and workpiece geometries are created by using CAD package techniques. The cutting edge, the chip shape coordinates, the shear angles and the interface contact length values, in each discrete element of the cutting edge, are determined from experimental and analytical formulations and integrated into the CAD model in order to regenerate as possible the real model geometry. The numerical simulation predicting temperature distribution in tool, chip and workpiece is performed with Abaqus code where thermal loads in primary and secondary shear zones take into account the variation of cutting conditions. The results of the numerical analysis are in agreement with cutting heat energy balance and experimental temperature measurements reported in the literature.
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