Multi-physics analytical modeling of the primary shear zone and milling force prediction

A wide variety of complicated material removal methods and cutting tools have been employed in the field of mold forming. An insight should be gained into the action law of basic cutting parameters and tool structure on cutting force, which lays a solid basis for the design of machine tools, tools and fixtures in mold high-performance manufacturing. In this study, an analytical model of milling force for milling H13 steel is built by combining the multi-physical field calculation method of cutting deformation zone and the equivalent cutting edge theory. A multi physical field calculation method for the first deformation zone is proposed in combination with the common correlation between the equal and unequal models of the main shear zone. The model correctly indicates the distribution characteristics of temperature and stress in the shear zone, consistent with the distribution of the two-dimensional (2D) finite element model. Given the changes of cutting parameters and tool geometric angles, the chip flow angle prediction model of different tool-chip contact states is built. The oblique cutting force prediction model is implemented through coordinate conversion based on the equivalent cutting edge. The interaction mechanism of tool geometry and tool angle on cutting force components is revealed, respectively. A mechanical model of the three-dimensional (3D) face milling process of H13 steel is built to more effectively verify the feasibility of the machining mechanical model, and the effect of milling parameters on the milling process force is expressed. The correctness of the model was verified by experimentally measuring the milling force. The built analytical cutting force model can lay a theoretical basis for the recommendation of reasonable tool structure and milling parameters for H13 steel.