Thermal modelling of end milling

Abstract

Determination of the temperatures during machining is one of the most important challenges for accurate milling simulations. Coupled with excessive shearing, plastic deformation and friction in a small region of cutting, the temperatures in milling may have very significant impact on parts and tools such as dimensional errors, residual stresses and tool wear. Temperature exhibits a non-linear complexmodelling problem in milling process. In this article, for the first time, a novel thermal modelling is introduced for fast and accurate prediction of temperatures in end milling processes. A theoretical modelling approach and experimental validations are presented for various cutting conditions. (C) 2014 CIRP.