3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of aluminum 6061-T6

Ali Davoudinejad*, Paolo Parenti, Massimiliano Annoni

*Corresponding author for this work

Research output: Contribution to journalJournal articleResearchpeer-review

Abstract

Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling (3D FEM) approach for the micro end-milling of Al6061-T6. Finite element (FE) simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects of mill helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.

Original languageEnglish
JournalFrontiers of Mechanical Engineering
Volume12
Issue number2
Pages (from-to)203-214
ISSN2095-0233
DOIs
Publication statusPublished - 2017
Externally publishedYes

Keywords

  • 3D finite element modeling
  • burr formation
  • chip formation
  • cutting force
  • micro endmilling

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