Modélisation thermomécanique du fraisage de forme et validation expérimentale

Abstract : he prediction of cutting forces in machining is essential to enhance NC codes and then contributing to improve reliability, accuracy and productivity in CNC machining. In fact, it may give information about cutter deflection, machine tool chatter, tool wear and breakage, and then tool life and surface integrity can be optimised in selecting appropriate cutting conditions. The aim of this work is to propose an original and predictive model for milling operations using the oblique cutting approach developed and validated by Moufki et al. (2004) based on the study of adiabatic shear banding in orthogonal cutting conducted by Dudzinski & Molinari (1997). The cutting forces calculation is then achieved by introducing the thermomechanical behaviour of the workpiece material and tool-chip interface friction characteristics. The tool is decomposed into a series of elementary disks, and then the milling operation is supposed carried out by a series of infinitesimal cutting edge elements in oblique cutting position. The geometrical model necessary to perform the forces calculation is developed for a 3-axis milling configuration by considering the tool geometry, tool path, tool engagement in workpiece material and even tool run-out to reproduce its huge effect on cutting forces. The obtained model is applied to slotting and ball-end milling of a sculptured surface and of an inclined surface. These tests are very useful to validate a complete process modelling and to obtain information about the influence of cutting conditions on cutting forces. In addition, this experimental validation gives some information about dry cutting of a 42CrMo4 steel.
Mots-clés : Fraisage-Métaux
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Theses
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Michaël Fontaine. Modélisation thermomécanique du fraisage de forme et validation expérimentale. Autre. Université Paul Verlaine - Metz, 2004. Français. ⟨NNT : 2004METZ028S⟩. ⟨tel-01750060⟩

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