Mathematical Modelling And Numerical Simulation Of

Forces In Milling Process

Bhanu Murthy Turai1, Cherukuvada Satish1, Prakash Marimuthu K1,a)
1
Department of Mechanical Engineering, Amrita University, Bengaluru, India
.
a)
Corresponding author: prakashkmuthu@gmail.com

Abstract: Machining of the material by milling induces forces, which act on the work piece material, tool and which in
turn act on the machining tool. The forces involved in milling process can be quantified, mathematical models help to
predict these forces. A lot of research has been carried out in this area in the past few decades. The current research aims
at developing a mathematical model to predict forces at different levels which arise machining of Aluminium6061 alloy.
Finite element analysis was used to develop a FE model to predict the cutting forces. Simulation was done for varying
cutting conditions. Different experiments was designed using Taguchi method. A L9 orthogonal array was designed and
the output was measure for the different experiments. The same was used to develop the mathematical model.

INTRODUCTION

Machining, is a manufacturing processes used in production of components or products and is done by material
removal method. Machining is a plastic deformation process. Our present work is on simulation on milling and chip
formation at micro level. The amount of forces are induced in the work piece are determined using the FEM. The
cutting parameters milling process that are varied are speed, feed and depth of cut. Prediction of the forces helps in
product design and many work has been carried out to predict the forces .Recently, aluminum alloys which have
good properties compared to other metals are being studied at a deeper level. Aluminium alloys have been thought
of as substitute for other metals. Hence, in this work the authors have worked on Al 6061 alloy.

FINITE ELEMENT MODELLING

Simulation help researchers to understand flow, structural, shop floor, fluid structural interactions problems at
microscopic levels. Researchers have used plain strain model to simulate the machining processes .A 2D plain strain
model was developed using a commercially available Finite element analysis software. In the model, the work piece
is modelled as deformable the tool is modelled as rigid body. The work piece is assigned with Al 6061 alloy as
material. The finite element analysis involves material model and damage model since the material undergoes severe
plastic deformation. In this work Johnson-cook material model in conjugation with Johnson-Cook damage model is
used to have a more realistic approach. The Johnson-Cook material model is given in TABLE 1. and damage values
are given in TABLE 2.

TABLE 1. J-C material model constants for Al 6061 alloy.

Material A(MPa) B(MPa) C n m
Al 6061-T6 324 114 0.002 0.42 1.34
 TABLE 2. J-C Damage model constants.
Materials D1 D2 D3 D4 D5 Tmelt Troom
Al 6061-T6 -0.77 1.45 -0.47 0 1.6 650◦C 20◦C

All degrees of freedom in arrested at the base of the work piece. The tool is allowed to rotate and move in the
“X” direction only. The tool is having 4 teeth to minic a four flute milling cutter. An Explicit/Dynamic analysis was
run until one complete pass was completed. The Finite element model is shown in FIGURE 1.

FIGURE 1. Meshed milling process model.

The zone which forms the un-cut chip thickness is more important to us hence the work piece is partitioned as
shown in Figure 2. and the top most partition which forms the un-cut chip is made of fine mesh. This helps in
reducing the computation time also. The total length of the work piece is 5 mm and the height is 1.25 mm.

FIGURE 2. Work piece showing the partition.

 DESIGN OF EXPERIMENTS

Design of experiments helps the researchers to reduce the number of experiments that need to be conducted,
without compromising the quality of the research that is carried out. Using Taguchi technique L9 orthogonal array
was generated. The different factors that were considered are Speed, feed and depth of cut. Three factors and three
levels were considered details of which is shown in TABLE 3. and the simulations were performed. The L9
orthogonal array is shown in TABLE 4. along with the responses.
TABLE 3. Factors and Levels.
Factors Level-1 Level-2 Level-3
Depth of cut X1 0.05 0.10 0.15
CUTCUCUCUTcut(mm)
Speed (rpm) X2 5000 4500 4000
Feed rate in mm/min X3 1500 1700 2000

TABLE 4. L9 orthogonal array with the responses.

DOE X1 X2 X3 Forces
1 0.05 5000 1500 59.50078
2 0.05 4500 1700 66.8558
3 0.05 4000 2000 85.8239
4 0.10 5000 1700 78.8555
5 0.10 4500 2000 111.2989
6 0.10 4000 1500 73.0095
7 0.15 5000 2000 125.6264
8 0.15 4500 1500 86.0901
9 0.15 4000 1700 114.8863

The responses shown in TABLE 4. were obtained from the FEM simulation. FIGURE 3 and FIGURE 4 how the
variation of force and Von Mises stress plot respectively.
 FIGURE 3. Variation of Force with respect to time

FIGURE 4. Von Mises Stress plot along with chip formation.

MATHEMATICAL MODELLING
Regression analysis was carried out on the obtained data. The regression analysis results are shown in TABLE 5
and TABLE 6.

TABLE 5. Regression analysis results

Regression Statistics
Multiple R 0.973967306
R Square 0.948612312
Adjusted R Square 0.9177797
Standard Error 6.606301558
Observations 9

TABLE 6. ANOVA and Regression analysis

Df SS MS F Significance F
Regression 3 4028.250535 1342.75 30.7665239 0.001196879
Residual 5 218.2161014 43.64322
Total 8 4246.466637

Coefficients Standard Error t Stat P-value

Intercept -54.72840368 31.11575785 -1.75886 0.13892642
X1 381.4077333 53.94022635 7.070933 0.000875152
 X2 -0.003245673 0.005394023 -0.60172 0.573602945
X3 0.069402925 0.010716836 6.476065 0.001308401

The significance F value is less than 0.005 which indicates that the factors taken for the analysis is appropriate.
The P-value less than 0.005 for depth of cut and the feed rate indicate that they are more significant in affecting the
force. The mathematical model that was developed is shown in Eqn 1.

CONCLUSION AND FUTURE WORK

A 2D finite element model was developed using a commercially available software. Using Taguchi method the
design of experiments was carried out and the simulation were performed using the L9 orthogonal array. Using the
output obtained from the simulations the mathematical model was developed.
 The mathematical model can predict the forces to 95% confidence level within the given conditions.
 Apart from force analysis, stress variation, temperature variation can be studied using the developed
model.
 Future work would involve development of thermos mechanical model.
 Future work also involves optimization of the cutting parameter using advanced algorithms like Genetic
algorithm, simulated annealing, particle swarm optimization.

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