3D Eulerian Finite Element Modelling of End Milling

In this article, a 3-dimensional Eulerian finite element method (FEM) model is introduced for simulation of end milling processes based on Abaqus/Explicit. Through the Coupled Eulerian Lagrangian (CEL) approach in model formulation, the chip formation process does not rely on the degradation of material or continuous remeshing algorithms to achieve chip separation. The process under investigation is the slot milling of Al6061-T6. A linear motion of the workpiece is adopted as a simplification of the trochoidal motion of the end mill. The workpiece is given a sinusoidal profile to achieve a varying uncut chip thickness in the cutting process. With a stationary tool and a confined region of mesh refinement, the computational cost of the model can be minimized. The model demonstrates good accuracy in cutting force predictions. The prediction error of the resultant cutting forces can be controlled within 12%. The proposed model also gives accurate predictions in terms of the morphology of chips. The excessive curling of chips in the early stages of chip formation can be predicted in the simulation process. The information obtained from the FEM model will provide more insights into the interactions between the cutting tool and the workpiece.