Numerical Simulation of Milling Using Inserts with Structural Gradients

摘要

Temperatures and stresses in milling inserts with structural gradients were211u001ecalculated with finite element analysis. Experimentally determined cutting 211u001eforces, chip thickness and tool/chip contact length were used as input data to 211u001ethe simulations. Inserts with two different coatings were studied, one with 211u001econventional CVD coating and one with plasma CVD coating. In both cases the 211u001egradient material consisted of a y-phase depleted zone, about 30 um thick, 211u001ebetween the substrate and the coating. Orthogonal up milling with a hard 90 211u001edegrees exit was studied. A two-dimensional model was set up. From known 211u001edistributions of loads in can generate temperature variations and in a second 211u001estep the stresses including both the thermal stresses and the stress from the 211u001emechanical loading. The load distributions were mainly determined from the 211u001eexperimental data.