3D heat transfer analysis for a hybrid approach to predict residual stresses after ball-end milling

A hybrid approach is developed to predict the residual stresses field induced by ball-end milling. This hybrid approach consists, first in the determination of a thermal mechanical loading equivalent to the metal cutting process and, second, to a 3D Finite Element analysis simulating the effect of this thermal mechanical loading on to the final workpiece. This work is focused on a 3D heat transfer analysis developed to predict the thermal loading along the flutes of the tool, considering elementary cutting forces derived from measurements made during orthogonal cutting tests and milling tests. The predicted temperature fields are compared with Infra-Red camera and thermocouples measurements. Residual stresses profiles derived from the complete hybrid approach are favourably compared with the results of experimental measurements made on flat specimens made of a 25MnCrSiVB6 bainitic steel. (C) 2012 Published by Elsevier Ltd. Selection and peer-review under responsibility of Prof. E. Brinksmeier