Stress-strain analysis of end milling HSS cutters reflecting the wear process

presentation

English

The paper deals with a stress-strain analysis of the end milling HSS cutters used frequently in the nowadays practice. Three geometrical CAD models of the tools have been worked out - SolidWorks 2007, STL mesh (generated by ATOS II SO scanner and support of ANSYS ICEM CFD - MCAE Systems), and a re-constructed Tebis - MCAE STL model. A deflection of the tool has been calculated for a real mechanical long-term loading, measured by the Kistler 9257B dynamometer. The mesh of finite elements was made by tetrahaedrons of the size 0.5 mm, but a refinement to 0.3 mm was made for the loaded edge areas. FEA ANSYS program/Ansys Workbench were used for calculations of cutting tool deformations according to real wear progress. Statistical assessment was done by Statgraphics v.5. Three places of stress concentration have been found, generally at the same locations for sharp and worn tools - roots of teeth, end of the flute (run out of a grinding wheel) and the place of tool clamping to the holder. The total stress value was under the strength limit for static and dynamical loading anyway. Prevailing abrasive mode of wear on flank and rake has been observed with the electron analytical microscopy. STL geometry of a real cutting tool can be recommended for such stress and deformation calculations, because time consumption for the design and calculations is shorter compared to the reconstructed model and approximately the same calculating accuracy acquired (20 minutes compared to several hours at powerful workstation HP9300).

FEA wear HSS cutter

PÍŠKA, M.; ZOUHAR, J.; POLZER, A.

29. 1. 2009

CIRP

Paříž, Francie

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