Modeling Static Cutting Forces And Stresses in the Face Milling Inserts

This study has analyzed the mechanical processes that would lead to an optimal design of indexed milling tools that have WC inserts. This thesis deals with the finite element stress analysis at the rake face of milling inserts with three dimensional shape. It was idealized by simplifying cutting forces uniformly distributed loading and elastic behavior was assumed.. Simulation was run on tungsten carbide specimens. Firstly, the shape of the insert cutting edges under the varying angles of the inserts were suggested. Then, an observed cutting force model was made. This permits analyzing the outcomes of the finite element stress on the cutting forces. A time-sensitive analysis was also made to observe the dynamic cutting forces and utility for the milling process. Afterwards, the models were put in a computer program to make the protocols of the models. The results show that there is a local maximum tensile stress on the rake face of the insert. It is also shown that there exist high shear stresses near the insert edge and that the normal stress decreases exponentially from a maximum value at the loading tool edge to minimum value at the other side of the insert. Results obtained are similar to those of orthogonal cutting but very much dependent on the shapes of the insert.