A realistic 3D finite element model for simulating multiple rotations of modified milling inserts using coupled temperature-displacement analysis

A 3D finite element model was developed to simulate the flat end milling operation by using two cutting inserts having side flank face textures combined with cutting edge micro-serrations. Coupled temperature-displacement analysis was performed by using a general-purpose software, Abaqus/Explicit. A slot at full radial immersion was cut on the workpiece by performing simulations for multiple rotations of the inserts. The novelty of the work is in avoiding the assumption of predefined chip geometry, in combining several important aspects in a single model as well as in making the appropriate advancement of the tool in to the workpiece during multiple rotations. All these phenomena make the model more realistic. The chip geometry was not predefined unlike various works reported in other studies. The model was validated by experimental results. The temperature of the finished surface predicted by the model was compared with the experimentally measured temperature. It was found that the prediction error for the temperature was about 6.1% only. The model was also able to successfully predict the chip morphology similar to that obtained during experiments. The robust novel model proposed in this study can further be utilized easily for performing investigations into the field of cutting tool modification.