Title: Investigations on the adjustment of the modelling section in 2D simulations of milling processes

Authors: E. Uhlmann, A. Mattes, M. Graf von der Schulenburg, Robert Gerstenberger

Addresses: Institute for Production Systems and Design Technology, Fraunhofer Gesellschaft, Pascalstr. 8-9, Berlin 10587, Germany. ' Fraunhofer Gesellschaft, Institute for Production Systems and Design Technology, Pascalstr. 8-9, Berlin 10587, Germany. ' Institute for Machine Tools and Factory Management, Technische Universitat Berlin, Sekr. PTZ 1, Pascalstr. 8-9, Berlin 10587, Germany. ' Institute for Machine Tools and Factory Management, Technische Universitat Berlin, Sekr. PTZ 1, Pascalstr. 8-9, Berlin 10587, Germany

Abstract: Conducting 3D simulation of milling processes still causes high efforts. There, only small workpiece sections can be modelled so far, instead of the entire contact width. Approaches using 2D simulation pose an interesting alternative. Here, the two-dimensional perspective is gained by dividing the workpiece into different sections perpendicular to the feed rate. This, however, requires a modelling approach that covers arbitrary contact widths along with a high mesh density in the area of chip formation. Automatically adjusting the modelling section hereby helps to model contact width up to 180° by segmentally simulating the rotation of the milling cutter. This paper presents the investigations on the effect of the most important parameters which influence sufficiently accurate computation of the equivalent cutting forces as in conventional 2D simulation models using the software DEFORM 2D.

Keywords: milling; finite element method; FEM; 2D simulation; modelling.

DOI: 10.1504/IJMMM.2009.026928

International Journal of Machining and Machinability of Materials, 2009 Vol.6 No.1/2, pp.69 - 82

Published online: 09 Jul 2009 *

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