Effect of Declination Angle on the Side Milling Process of Ti6Al4V by a New Three-Dimensional Milling Finite Element Model

Milling is one of the commonly used processing methods. The spindle of milling cutter is likely to be inclined when assembly error exists or complex surface is machined with multi-axis machine tool, thus reducing the machining accuracy. In this work, a three-dimensional (3D) finite element model (FEM) of side milling is established by using finite element software ABAQUS. This work describes the plastic deformation of materials using the J-C constitutive model considering strain, strain rate and temperature. J-C damage model is then used as the failure criterion of materials. The constructed FEM is verified by comparing with those established in the existing literature. Then, based on the established 3D milling FEM, the influence of feed speed and spindle declination angle on the side milling process is studied. Finally, chip formation process is analyzed, and milling force, stress and temperature distribution are obtained. The results show that the radial milling force F-x is most affected by the declination angle of spindle, whose peak value will obviously increase as the declination angle of spindle increases in the milling process, accompanied by stronger curl in chip. [GRAPHICS] .