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Investigations on the adjustment of the modeling section in 2D simulation of milling processes

Untersuchungen zur Justierung der Modellierungssektion bei der zweidimensionalen Simulation des Fräsprozesses
: Uhlmann, E.; Mattes, A.; Zettier, R.; Graf von der Schulenburg, M.

Micari, F.; Filice, L. ; University of Calabria, Rende:
10th CIRP International Workshop on Modeling of Machining Operations. Proceedings : August 27-28, 2007, Reggio Calabria, Italy
Rende: University of Calabria, Department of Mechanical Engineering, 2007
ISBN: 978-88-95267-04-3
International Workshop on Modeling of Machining Operations <10, 2007, Reggio Calabria>
Fraunhofer IPK ()
Fräsen; Simulation; Modellieren=Gestalten; Justierung; Werkstück; Vorschubgeschwindigkeit; Kontakt=Reibung; Maschendichte; Spanbildung; Fräser; Schnittkraft; Simulationsmodell; Software; mechanische Spannung; Rechenzeit

Conducting 3D simulation of milling processes still causes high efforts. There, only small workpiece sections can be modeled so far, instead of the entire contact width. Approaches using 2D simulation pose an interesting alternative. Here, the two-dimensional perspective is gained by dividing the workpiece into different sections perpendicular to the feed rate. This, however, requires a modeling approach that covers arbitrary contact widths along with a high mesh density in the area of chip formation. Automatically adjusting the modeling section hereby helps to model contact width up to 180 deg by segmentally simulating the rotation of the milling cutter. The paper presents the investigations on the effect of the most important parameters which influence sufficiently accurate computation of the equivalent cutting forces as in conventional 2D simulation models using the software DEFORM 2D. The operational reliability of the model was verified by a newly conducted simulation conducted using the new simulation model, with which the points in time of the adjustments for a model section were not recognizable at the cutting force distribution. In addition a realistic cutting force plot for milling operation was realised and the stress occurring at the end of a workpiece section could be held on a constant level. Undesired variations compared to simulations without adjustment of the modelling sections were limited on an area behind the tip of the cutting wedge. There, risings in stress occur inside the workpiece after modifications of the model. An influence on the cutting force however was not observable. Thus, the new simulation model accomplishes the requirements for the simulation of long cutting distances at reduced computing time. However, further studies will have to show, how applicable these results are for other simulation parameters.
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