Three-dimensional rigid-viscoplastic finite element simulation of milling process

A three-dimensional thermo-mechanical coupled model of milling process has been developed using the rigid-viscoplastic finite element theory. Three-dimensional milling cutter model with spiral teeth and variational thickness cutting layer model are used in the new FEM model. Adaptive remeshing technique based on error estimate is adopted to control the computation scale and simulate the separation of thin cutting layer. The dynamic variation law of milling force and milling temperature are discussed. Simulation results show that the helix angle have significant effect on the milling force and temperature. At entry of each tooth into workpiece, the variation of temperature of milling cutter is much larger than that at exit, which agrees with the experimental measured results in the literature.