Unidirectional coupled finite element simulation of thermoelastic TCP-displacement through milling process caused heat load

The paper presents a numerical simulation of thermal induced tool displacement during milling oper-ation. An unidirectional finite element model is developed which consists of two sections. A CFX model and a thermal transient model. With the aid of CFX module, the conjugated heat transfer be-tween milling tool and coolant fluid is described. The result of these efforts is the body temperature field of the end mill cutter due to thermal load, which is the thermal fingerprint of the cutting process. Subsequently the calculated body temperature field is linked with a transient-structural module to cal-culate the resulting thermal elastic displacement of the milling cutter. The thermo-elastic displace-ment of the tool is determined by examining a pilot node at the tip of the end mill, whose displace-ment is calculated in relation to the global coordinate system of the model.