Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

Abstract

In this present work, finite element analysis (FEA)-based simulation of end-milling of AISI1045 steel using tungsten carbide tool was performed using DEFORM-3D simulation software. Usui tool wear model, Johnson-cook material model and adaptive remeshing are considered during machining simulation. The impact of machining variables rate of feed, tool speed, and depth of cut was investigated, and the best integration of variables was distinguished for lower cutting temperature, principal stress, cutting forces, effective stresses, tool wear, and effective strain. The obtained results were correlated using experimentation in a vertical machining center attached with a Kistler tool dynamometer with data acquisition setup for capturing the cutting forces, and an infrared (IR) thermometer was used to measure the cutting temperature, and a comparison was done. Results showed a good correlation. There is a relationship between experimental and numerical results, and simulation findings can be utilised for interpreting the influence of machining parameters.

Analyzing the Effect of Temperature on Alloy Steel Forging Simulation Using Finite Element Simulation

“…The forming process uses the Johnson-Cook material model and the Lagrangian incremental (LE) method of mathematical formulation. Equation 2 illustrates the strain rate and temperature dependent equation for the work piece's isotropic behavior with deformable thermo-viscoplastic property [26].…”

“…This experiment demonstrated that the needed creep qualities should meet using the non-isothermal processing technique with the correct thermomechanical process parameters selection. The experiment was conducted on AISI1045 steel end-milling with a tungsten carbide tool and used finite element analysis-based modeling using DEFORM-3D software to minimize temperature, stress, thrust force, tool wear geometry, and strain [26].…”