Investigations on the adjustment of the modelling section in 2D simulations of milling processes

Conducting 3D simulation of milling processes still causes high efforts. There, only small workpiece sections can be modelled 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 modelling approach that covers arbitrary contact widths along with a high mesh density in the area of chip formation. Automatically adjusting the modelling section hereby helps to model contact width up to 180° by segmentally simulating the rotation of the milling cutter. This 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.