Finite element chip formation analysis for high speed milling operations

High speed end milling of hardened steel offers several advantages over EDM in die/molds applications especially due to recent development in machine tools, spindles and controllers. However successful implementation of this technology is limited mainly due to faster tool wear and undesirable surface properties. Finite element modeling and simulation techniques are capable of optimizing the cutting conditions and tool geometry by predicting the temperature and stresses distributions. In this study a finite element model has been developed to predict cutting forces, temperature and stresses distributions in flat end milling processes of hardened steel using PCBN at high cutting speeds. High speed end milling experiments were conducted using flat bottom end mills with single insert having straight cutting edge. Comparison of simulated and experimental cutting forces data shows reasonable agreement at high speed regime using the developed model.