DYNAMIC FEED RATE SCHEDULING IN MESO-SCALE MILLING PROCESSES

Abstract

This study aims to establish an intellectual method of selecting feed rate in meso-scale rough milling processes. This process requires appreciations of two fundamental sub-topics: investigation of the cutting mechanics through modelling of meso-scale milling process, and stress analysis and breakage prediction of the cutting tool. A 3D Coupled Eulerian Lagrangian (CEL) Finite Element Method (FEM) model is introduced for the simulation of meso-scale end milling processes based on Abaqus/Explicit. The FEM model gives accurate predictions in terms of cutting forces and chip morphology. Based on the contact forces obtained from the simulation, tool stress analysis and breakage prediction are then advanced for meso-scale shoulder milling processes. Finally, a stress based feed rate scheduling algorithm is formulated based on the developed FEM models. Through feed rate scheduling, tool breakage can be prevented while having an optimum material removal rate in meso-scale rough milling processes.