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A FEA simulation study of ball end mill for fixed 3+1 / 3+2 axis machining of Ti-6Al-4V.

Anbalagan, Arivazhagan; Arumugam, Eakambaram; Michael, Anthony Xavior

Authors

Eakambaram Arumugam

Anthony Xavior Michael



Abstract

This paper presents a Finite Element Analysis (FEA) simulation study conducted on ball endmill for fixed 3 + 1 and 3 + 2 axis orientations for machining Ti-6Al-4 V. This work adopts a tungsten carbide (WC) ∅18.6 mm diametrical/6fluted ball endmill to analyse maximum principal elastic strain (ϵmax-max-principal-elastic), maximum principal stress (σmax-principal)along with cutting tools forces in the axial (Fz), radial (Fy), tangential (Fx) and total (Ftotal) directions. The machining orientations considered for 3 + 1 and 3 + 2 axis are (i) tilt angles of 5°, 10°, 15° & 20° and (ii) lead angles of 5°, 10° & 15° with a constant fixed tilt angle of 10°. The cutting speed and feed rate per tooth is taken as 450 m/min and 0.5 mm/tooth. These are based on a high speed machining (HSM) scenario and has been dynamically simulated for a maximum of 175,000 cycles. From the simulation study considered at 16-20 valid cutting points, it can be noticed that in 3 + 1 axis, for a tilt angle of 10° and 3 + 2 axis for a Tilt 10°/Lead 10° the σmax-principaland ϵmax-max-principal-elasticare higher when compared with all tilt/lead angles. In case of total forces (Ftotal) from all 3 directions (Fx, Fyand Fz) not much variation can be noticed for different tilt/lead angles, but higher values are recorded with 3 + 1 axis at 5° tilt angle and 3 + 2 axis at tilt/lead angle of 10°. The paper provides a critical comparative study on the 3 + 1/ 3 + 2 axis orientations highlighting the cutting strain/stress with tool forces at valid cutting points considering entry, middle and exit region of the blank by emphasizing the importance of cutting tool design parameters.

Citation

ANBALAGAN, A., ARUMUGAM, E. and MICHAEL, A.X. 2021. A FEA simulation study of ball end mill for fixed 3+1 / 3+2 axis machining of Ti-6Al-4V. Materials today: proceedings [online], 46(17): proceedings of 3rd International conference on materials, manufacturing and modelling 2021 (ICMMM 2021), 19-21 March 2021, [virtual conference], pages 7803-7814. Available from: https://doi.org/10.1016/j.matpr.2021.02.369

Journal Article Type Conference Paper
Conference Name 3rd International conference on materials, manufacturing and modelling 2021 (ICMMM 2021)
Conference Location [virtual conference]
Acceptance Date Feb 8, 2021
Online Publication Date Mar 6, 2021
Publication Date Dec 31, 2021
Deposit Date Mar 15, 2021
Publicly Available Date Mar 7, 2022
Journal Materials Today: Proceedings
Electronic ISSN 2214-7853
Publisher Elsevier
Peer Reviewed Peer Reviewed
Volume 46
Issue 17
Pages 7803-7814
DOI https://doi.org/10.1016/j.matpr.2021.02.369
Keywords 3+1/3+2 axis; Ti-6Al-4V; Tilt/Lead angle; Finite element analysis; Machining; Tool forces; Stresses and strains
Public URL https://rgu-repository.worktribe.com/output/1255614