Evaluation of cutting edge micro-geometry in milling of 316L stainless steel: A study based on FEM

Abstract

Abstract The objective of this research is to simulate the cutting edge micro-geometry in machining a stainless steel (SUS-316L). The accurate finite element method (FEM) are verified by cutting edge preparation and cutting experiments at solid carbide end mills. The cutting edges are prepared by drag finishing. Utilizing this preparation method, the prepared cutting edges have three kinds of roundness profile with symmetry (K=1) and asymmetry (K=0.5 and K=2), which is considered for the modelling. We explored the chip formation, plastic strain and residual stress, mises stress and distribution of temperature, and also tool-chip contact length and the effective rake angle γeff with three different symmetry (K=1) and asymmetry (K=0.5 and K=2) also be examined. The simulation results suggest that waterfall tools (K=0.5) can increase stress strain and peak cutting temperature compare with other cutting edge micro-geometry. At the same time, the trumpet tools (K=2) also have a great influence on sub-surface and surface stress distribution. Therefore, the cutting edge segment on the flank face Sα has significant the metal cutting process.