A full factorial numerical investigation and validation of precision end milling process for hardened tool steel

Research output: Contribution to conferencePaper

1 Citation (Scopus)

Abstract

Tool steel materials have poor machinability, as the high hardness of the material will cause high cutting forces, premature failure of the cutting tools, and is also associated with machining induced tensile stresses within the work piece. Due to high experimental costs, there is no recent research on end milling tool steel, using full factorial experimental or numerical design. A 3D FE-model of a precision end milling process with a two flute ball nose cutter were established in this paper. The FE-Model used a subroutine to model hardening realised through the Johnson-Cook model, additionally were a material removal criteria developed and implemented. Through full factorial numerical simulations the influence of cutting parameters on cutting force of H13 tool steel was studied. Depth of cut was found to be the most influential machining parameter on cutting forces followed by feed rate and surface speed. Four milling experiments were carried out to validate the simulation results. It was found that the simulation and the experiments had a good agreement on the cutting forces. The validated FEA model can be used for further studies on residual stress or temperatures and to optimise the cutting process.

Conference

Conference17th euspen International Conference & Exhibition
CountryGermany
CityHanover
Period29/05/172/06/17
Internet address

Fingerprint

Tool steel
Machining
Machinability
Subroutines
Cutting tools
Tensile stress
Hardening
Residual stresses
Experiments
Hardness
Finite element method
Computer simulation
Costs

Keywords

  • FEM
  • end milling
  • hardening
  • tool steel
  • HSM

Cite this

@conference{30cf9d5c7532499681c81330a6519280,
title = "A full factorial numerical investigation and validation of precision end milling process for hardened tool steel",
abstract = "Tool steel materials have poor machinability, as the high hardness of the material will cause high cutting forces, premature failure of the cutting tools, and is also associated with machining induced tensile stresses within the work piece. Due to high experimental costs, there is no recent research on end milling tool steel, using full factorial experimental or numerical design. A 3D FE-model of a precision end milling process with a two flute ball nose cutter were established in this paper. The FE-Model used a subroutine to model hardening realised through the Johnson-Cook model, additionally were a material removal criteria developed and implemented. Through full factorial numerical simulations the influence of cutting parameters on cutting force of H13 tool steel was studied. Depth of cut was found to be the most influential machining parameter on cutting forces followed by feed rate and surface speed. Four milling experiments were carried out to validate the simulation results. It was found that the simulation and the experiments had a good agreement on the cutting forces. The validated FEA model can be used for further studies on residual stress or temperatures and to optimise the cutting process.",
keywords = "FEM, end milling, hardening, tool steel, HSM",
author = "Andreas Reimer and Stephen Fitzpatrick and Xichun Luo",
year = "2017",
month = "5",
day = "29",
language = "English",
note = "17th euspen International Conference & Exhibition ; Conference date: 29-05-2017 Through 02-06-2017",
url = "http://www.euspen.eu/events/17th-international-conference-exhibition/",

}

Reimer, A, Fitzpatrick, S & Luo, X 2017, 'A full factorial numerical investigation and validation of precision end milling process for hardened tool steel' Paper presented at 17th euspen International Conference & Exhibition, Hanover, Germany, 29/05/17 - 2/06/17, .

A full factorial numerical investigation and validation of precision end milling process for hardened tool steel. / Reimer, Andreas; Fitzpatrick, Stephen; Luo, Xichun.

2017. Paper presented at 17th euspen International Conference & Exhibition, Hanover, Germany.

Research output: Contribution to conferencePaper

TY - CONF

T1 - A full factorial numerical investigation and validation of precision end milling process for hardened tool steel

AU - Reimer, Andreas

AU - Fitzpatrick, Stephen

AU - Luo, Xichun

PY - 2017/5/29

Y1 - 2017/5/29

N2 - Tool steel materials have poor machinability, as the high hardness of the material will cause high cutting forces, premature failure of the cutting tools, and is also associated with machining induced tensile stresses within the work piece. Due to high experimental costs, there is no recent research on end milling tool steel, using full factorial experimental or numerical design. A 3D FE-model of a precision end milling process with a two flute ball nose cutter were established in this paper. The FE-Model used a subroutine to model hardening realised through the Johnson-Cook model, additionally were a material removal criteria developed and implemented. Through full factorial numerical simulations the influence of cutting parameters on cutting force of H13 tool steel was studied. Depth of cut was found to be the most influential machining parameter on cutting forces followed by feed rate and surface speed. Four milling experiments were carried out to validate the simulation results. It was found that the simulation and the experiments had a good agreement on the cutting forces. The validated FEA model can be used for further studies on residual stress or temperatures and to optimise the cutting process.

AB - Tool steel materials have poor machinability, as the high hardness of the material will cause high cutting forces, premature failure of the cutting tools, and is also associated with machining induced tensile stresses within the work piece. Due to high experimental costs, there is no recent research on end milling tool steel, using full factorial experimental or numerical design. A 3D FE-model of a precision end milling process with a two flute ball nose cutter were established in this paper. The FE-Model used a subroutine to model hardening realised through the Johnson-Cook model, additionally were a material removal criteria developed and implemented. Through full factorial numerical simulations the influence of cutting parameters on cutting force of H13 tool steel was studied. Depth of cut was found to be the most influential machining parameter on cutting forces followed by feed rate and surface speed. Four milling experiments were carried out to validate the simulation results. It was found that the simulation and the experiments had a good agreement on the cutting forces. The validated FEA model can be used for further studies on residual stress or temperatures and to optimise the cutting process.

KW - FEM

KW - end milling

KW - hardening

KW - tool steel

KW - HSM

UR - http://www.euspen.eu/events/17th-international-conference-exhibition/

M3 - Paper

ER -

Reimer A, Fitzpatrick S, Luo X. A full factorial numerical investigation and validation of precision end milling process for hardened tool steel. 2017. Paper presented at 17th euspen International Conference & Exhibition, Hanover, Germany.