Finite Element Simulation and Analysis of Size Effect in Micro-Milling Process

Abstract

In order to determine the minimum thickness of cutting under different cutting condition of aluminum alloy materials 2A12 of micro-milling, research the size effect caused by the cutting edge radius and few microns per tooth in micro-milling process. Using thermal coupling model of Johnson-Cook as a material model of the workpiece, using Johnson-Cook shear failure of the law as part of the failure criteria, using coupled plane strain thermal units and hybrid adaptive grid technology to mesh, the friction between the tool and workpiece take the amendment Coulomb's law that combine with the sliding friction areas and areas of the adhesive friction, to the micro-milling by nonlinear and elastic-plastic finite element simulation. Through finite element analysis, the ratio of minimum radius of thickness to the cutting edge tool radius under different conditions of cutting speed and cutter blade was got, the size effect, stress field and cutting force under different cutting depth was got, and comparing and analysis the results, getting the various factors impact on the size effect of micro-milling, it provide a basis for the actual processing.