Methodology of the numerical modeling of cutting for calculating the contact stress distribution: a case study on steel milling

This paper presents a general methodology for the numerical modeling of cutting using end milling as an example. The proposed multilevel model is specified with functional relations between the tool design parameters (shape of the end part, number of teeth, front and back angles), sharpness (radius of rounding) of the cutting edge, cutting modes (cutting speed, feed, cutting depth and width), physical and mechanical characteristics of the processed material, and the resulting equivalent Mises stresses in the cutting wedge of the milling tooth. The justification of the requirements for the finite element mesh is given. It is suggested to choose a rational option when splitting into elements. The assumptions of the model that allow reducing requirements to computing power without calculation quality losses, are justified.