FINITE ELEMENT APPROACH OF FACE END MILLING CUTTER “EXPECTED TOOL LIFE ESTIMATION”

Milling is highly used in manufacturing processes for the production of parts with required dimensions and shape. In an analysis of milling cutter the most important parameter is stress formation. Stress made along the finished edges and surfaces in milling activity have gigantic impact at surface quality and conduct of the finished parts and structures. Before the manufacturing, numerical analysis is performed to estimate the life of the tool by determining the stresses. In this present work, Finite Element (FE) Approach is used for designing accurately end mill cutting tools for milling of Titanium alloys by considering the stresses and forces developed on cutting tool. Design optimality of the end mill cutters of different sizes have been done by considering the tool forces to the minimum value. The three dimensional CAD models of the face end mill are created and Finite Element Analysis carried out by conforming the cutting tool forces for milling operation. By considering the titanium alloy as work piece material, the cutting tool forces, thermal variation of the cutting tool with the different geometry, tool wear, and stresses are simulated. This study leads to the development of optimal milling cutter design in order to achieve better tool life and quality of machined surface.