3D simulation of thermal-force distribution in high-speed ball end milling die steel

In order to obtain the thermal-force distribution state in the cutting process of high-speed ball end milling die steel and provide the basic data for the research on the thermal-force forming mechanism of machined surface, the 3D finite element modeling and simulation for the high-speed milling process of automobile covering parts die steel Cr12MoV was performed with the finite element process simulation system DEFORM based on the Lagrange algorithm. The chip formation process of ball end milling cutter was successfully simulated under the inclination angle of 15° in the model, the predicted cutting force in the feed direction, span direction and axial direction is in good agreement with the experimental data. The deviation between the simulated average cutting temperature on the shear plane and experimental data is within 10%. Furthermore, the simulated contour shape of cutting zone on the mold surface fits well with that of chip morphology in the high-speed milling, which can prove that the proposed 3D model can better reflect the thermal-force distribution in the cutting process.