A Finite Element Modeling Prediction in High Precision Milling Process of Aluminum 6082-T6

This study investigates micro-end-milling machining prediction using three-dimensional finite element modeling method. The FE model was developed for contouring up-milling operation for prediction of chip flow, burr formation, cutting temperature and cutting forces in an integrated model. The flow stress behavior of the workpiece was modeled by the Johnson–Cook material constitutive model. Different cutting conditions were simulated to consider the effect of the process variables that might be difficult or impossible to follow in the physical experiments at this scale. The tool was precisely 3D modeled to describe the detailed geometry of the tool which is one of the critical aspects of the model and is characteristic of the cutter tool micro-geometry design. Furthermore, the tool deflection was studied using a FE model under the experimental cutting forces measured in the different cutting conditions in order to consider the micro-end-mill deviation from the nominal position. 3D simulations of chip flow and temperature distribution are compared in various cutting conditions. The results of the burr formation, temperature distribution and cutting forces in three directions predictions are compared against the experiments. Simulations were able to predict the burr height with an accuracy between 1 and 4 µm depending on cutting parameters settings. The results of this study are beneficial to comprehend the micro-end-milling chip and burr formation to increase the machinability of the workpiece and to understand the influence of cutting parameter in order to prevent several experimental tests prior to the final machining.