### Dik kesme işleminin Lagrangian sınırlı sonlu eleman modeliyle küresel parmak frezeleme kuvvetlerinin incelenmesi

Mehmet AYDIN, Uğur KÖKLÜ
2018 Gazi Üniversitesi Mühendislik-Mimarlık Fakültesi Dergisi
Highlights: Graphical/Tabular Abstract • An Arbitrary Lagrangian Eulerian (ALE) finite element (FE) model with Lagrangian boundary • Using the unified mechanics of cutting approach to estimate ball-end milling forces • The estimated milling forces based on the orthogonal cutting database and oblique cutting model In this work, ball-end milling forces are investigated by the unified mechanics of cutting approach and finite element (FE) model with Lagrangian boundaries of the orthogonal machining
more » ... process. Two-dimensional FE model of the orthogonal machining operation is prepared to determine milling forces using this predictive approach. Fully coupled thermal-stress simulations are performed to establish the orthogonal machining outcomes in machining of 20NiCrMo5 steel by tungsten carbide tooling. Applying the oblique cutting theory, the orthogonal machining outcomes are carried to helical cutting tool geometry. Based on numerical and analytical solutions, the milling forces are determined for a range of cutting conditions. Purpose: The purpose of this study is to investigate cutting forces acting on ball-end milling cutter. Theory and Methods: The presented model is composed of two parts to determine ball-end milling forces: FE model with Lagrangian boundaries of the orthogonal machining process and the unified mechanics of cutting approach Results: The obtained results are summarized in the following two main categories: a) evaluation of orthogonal cutting data such as shear stress, friction coefficient and chip thickness ratio. b) analytical simulation results of ball-end milling forces. Conclusion: This study presents a process simulation method to estimate ball-end milling forces from the FE model of the orthogonal machining process. The first contribution of this study is to estimate the orthogonal cutting data required in the predictive force model from the proposed ALE FE technique with Lagrangian boundary condition. Its other contribution is that the ball-end milling forces are determined for a range of milling conditions using the unified mechanics of cutting approach. Boşluk açısı, γ (°) 6 Kesici kenar yarıçapı, rβ (µm) 20 Kesme koşulları Kesme hızı, Vc (m/s) 0,25−0,75−1,25−2,25−3,5 Kesilmemiş talaş kalınlığı, t (mm) 0,025-0,05-0,075-0,1−0,125 Kesme derinliği, a (mm)