Milling Process Parameters

Milling process parameters
ANSYS SIMULATION OF MILLING TOOL

Table of Contents
1. Methodology............................................................................................................................2
1.1 ANSYS Steps....................................................................................................................2
1.2 Major factors affecting the cutting tool life......................................................................8
1.2.1 Cutting Speed.............................................................................................................8
1.2.2 Physical Properties of Work Piece............................................................................8
1.2.3 Area of Cut................................................................................................................9
1.2.4 Ratio of Feed to Depth of Cut....................................................................................9
1.2.5 Shape and Angles of Tools......................................................................................10
1.2.6 Effect of Lubricant...................................................................................................10
1.2.7 Nature of Cutting.....................................................................................................10
2. ANSYS results.......................................................................................................................12
2.1 Aluminum work piece vs Titanium alloy cutting tool....................................................12
2.1.1 Von-Mises Stress.....................................................................................................12
2.1.2 Elastic Strain............................................................................................................12
2.1.3 Total Deformation...................................................................................................13
2.2 Stainless steel work piece vs Titanium alloy cutting tool...............................................13
2.2.1 Von-mises Stress.....................................................................................................13
2.2.2 Elastic Strain............................................................................................................14
2.2.3 Total Deformation...................................................................................................14
3. Summary of Findings.............................................................................................................15
4. Recommendations for improve tool life.................................................................................15
5. References..............................................................................................................................17
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1. Methodology
In this section of the methodology used for the analysis is explained. Here ANSYS 19.0 software
and Solid works software are used for the simulation and designing. Tool life and surface finish
of the product produced by the milling process mainly depends on the milling process
parameters. In general, there are a different set of milling parameters are there. Among them,
material properties are focused on this research. Here two different work materials and titanium
alloy cutting tool are simulated.
Cutting tool material is selected as titanium and its mechanical properties are given below.
 Tensile Strength 220 MPa
 Modulus of elasticity 116 GPa
 Shear Modulus 43 GPa
 Hardness Number 70 BHN
 Density 4.50 g/cc
 Melting Point 1670 C
 Poisson Ratio 0.34
 Thermal Conductivity 17 W/mK
Work Piece Material
 Aluminum
 Structured Steel
1.1 ANSYS Steps
Explicit dynamics is a simulation model that included the applied loads and interactions, setting
up the model, and solving the model in the nonlinear dynamic responsive method. The workflow
of the explicit dynamics is given in the following steps (An et al., 2014).
The first step is the creation of the analysis system. For creating the analysis, from the toolbox,
we need to expand the standard analysis folder. Then drag the template onto project schematic.
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In the analysis system consist of an array of cells, they are displayed in the vertical form and
each cell is denoted as a component of the system. To indicate every cell in the system need to
right-click the cell and choose the edit option. The explicit dynamic solver is a type of double
precision. The explicit dynamics support the ms, mm, and mg solver unit system. (Baron and
Rolland, 2015)
The second step is defining the engineering data. In this part, the properties of the material are
described. Based on the application the material properties are varied. The material properties
can be temperature dependent, nonlinear or linear. The nonlinear material, hyper elastic material,
and plasticity materials properties are present in the tabular format. The linear materials have
constant properties. If we use the material for the dynamic analysis means it must contain the
density. For each analysis, we have defined the material properties. Using the Engineer Data tab
we add materials to the material library. To perform any operations on materials, right-click the
Engineering Data tab and click the edit option.
The third step is to add geometry to the system. In explicit dynamics surface, line bodies, and
solid these are the geometry information are added. It also contains Stiffness behavior, system
coordinate, Reference temperature, rigid materials, and the reference frame. The explicit
dynamic analysis supports only symmetric cross-sections. This doesn't support the channel
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