The definition of cutting forces in square shoulder milling by 3D
The paper presents the 3D square shoulder milling study of modeling, using Smooth Particles Hydrodynamics methodology that also illustrate specific challenges and solutions. The aim of the study – define the cutting forces and to compare them to analytical models. The milling is discontinuous cutting and by each turn the chips are formed depending on the milling tool width and number of teeth. Then the simplification of complex cutting tools to one-point tool is not so informative and understandable for the numerical analysis. The main advantage of presented SPH methodology – less artificial numerical criterions needed for numerical solution. Also, shorter calculation time comparing to FEM and „natural“ chip removal process due to Kernel function. SPH metodology alloowed to use real 3D milling cutter and to perform the calculation according to feed rate, cutting speed and tool rotation. In order to provide the numerical simulation the simplified numerical tests were performed, according to the density of smooth particles and artificial bulk viscosity parameter. The model demonstrated satisfactory coincidence of computed results against the theoretically obtained data. Calculated tangential cutting force is in satisfactory correlation with theoretical Hulle hypothesis. Tne numerical instabilies seen in graphics of results coud be eliminated with SPH metodology, by using higher cutting speed (deformation rate).