A three dimensional finite element thermomechanical analysis of intermittent cutting process

A three dimensional thermo-mechanical tool/chip model is presented to simulate the intermittent end milling cutting process using a high speed steel tool. This model predicts the temperature distribution, thermal stresses as well as the mechanical stresses induced in the tool and the chip during both the cutting and non cutting periods. The effects of the width of cut, the cutting time/non cutting time ratio, and the variation of the properties with temperature are studied. The results of the analysis show that as the depth of cut and the cutting time/cooling time ratio increase, the maximum temperatures induced in the tool increase. Furthermore, the maximum temperature and the resulting thermal stresses are found to increase when the temperature dependent material properties are incorporated in the analysis. Finally, the use of the three dimensional model is found to be justifiable in view of the significant differences in the predicted temperatures and stresses as compared to those published for two dimensional analyses.