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Ponomaryov B. B., Nguyen S. H. Modeling and analysis of influence of process conditions on cutting forces during end milling. Modern technologies. System analysis. Modeling, 2018, Vol. 59, No. 3, pp. 8–16. DOI: 10.26731/1813-9108.2018.3(59).8-16

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The article presents simulation results for ball end milling and projection variation analysis results for cutting forces Fx, Fy and Fz at different depth of cut and feed per tooth.

The 2D and 3D models of milling dynamics based on the finite-element tool-surface interaction model were developed using SIMULIA Abaqus. As a tool, a ball end mill with a diameter of 2 mm was selected from high-speed steel P18, and the workpiece is a rectangular plate made of steel 45. Johnson-Cook models are used to specify the linear-elastic and mechanical material properties of tool and workpiece.

Computational finish milling simulation results at different cutting parameters can be used to predict the nature of loads on the tool depending on its design when developing control software for CNC-based mills. Taking into account strength and rigidity parameters, a reasonable choice of tools can improve equipment performance.

Dependency graphs of cutting forces on the tool rotation angle are given for different values of feeds per tooth and depths of cut. Comparing the results of modeling with theoretical conclusions and the existing results of experiments of other authors, the ABAQUS program was proved to work in the modeling and analysis of the cutting forces of end milling processes.

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