Finite element modeling of micro-milling: Numerical simulation and experimental validation

ABSTRACT

In this study, micro-milling of Inconel 718 was investigated. For this purpose, cutting tests were conducted by using uncoated tools and taking four different feed rates (1.25, 2.5, 3.75, and 5 µm/flute) and a constant cutting velocity (48 m/min) into account. In numerical modeling, thermomechanical behavior was modeled using the modified Johnson–Cook material model. Analyses were also conducted for different cutting tool edge angles (+8°, 0, and −8°). In the numerical analyses, cutting force, tool stress, and cutting temperature values were estimated depending on tool rotation and cutting tool edge type and compared with experimental results. When the results obtained from the study are considered, it is seen that the experimental cutting force and temperature values are in harmony with the numerical results. Moreover, it is seen that there is an increase in cutting force, cutting temperature, and stress values depending on the feed rate. In addition, in the numerical analyses for different cutting tool edge geometries it was observed that cutting force temperature and tool stress values varied depending on the edge geometries.

KEYWORDS:

• Finite element modeling
• Inconel 718
• micro-end milling

Acknowledgments

The authors would like to thank Bilkent University, Motion Sensors and Micro System Technologies Expertise and Excellence Centre (HAMİT) and Dr. Yiğit KARPAT for his contribution to the experimental phase of this study.

This work was supported by grants from the Scientific and Technological Research Council of Turkey (TUBITAK) from the Support Program for Scientific and Technological Research Projects (1001), project no: 213M572.