Stress-Strain Modelling in a Milling Process for a Thin-Walled Element

This paper presents selected aspects of stress-strain modelling in a thin-walled element after milling. The simulations on specimens of aluminium alloy EN AW-2024 T351 were conducted by the finite element method in Solid Edge using linear statics and Nastran iterative solver. Two sets of technological parameters were used: for roughing and finishing, respectively. To obtain real data for the simulations, preliminary tests were performed in order to determine selected mechanical properties of the material and to measure values of cutting force components. The results showed that the reduced stress obtained in the finishing operation was twofold lower than that obtained in roughing. This was primarily due to a smaller cross section of the machined layer and its relation to technological parameters such as the depth of cut and the feed per tooth as well as the width of cut. A similar relationship was observed for strain. It should be noted that numerical simulations can find application in practice, since exceeding the yield point of a material can cause permanent damage to the workpiece or, at least, lead to unacceptable machining errors. Moreover, this approach makes it possible to conduct cost-free analyses aimed at optimizing machining parameters in terms of achieving the required dimensional and shape accuracy.