Abstract
Improvement in machining efficiency requires better comprehension of multiphysical cutting process phenomenon under real dynamic cutting conditions. Present work suggests a multi-scale interaction of mesoscopic level cutting with macroscopic level machine tool dynamics to optimize cutting process parameters and potentially improve interactive design process. For that, the case of an orthogonal down-cut peripheral milling, for an aeronautic aluminium alloy A2024-T351, has been treated. A finite element based multi-scale dynamic cutting model has been conceived with a commercial finite element based code ABA-QUS (R)/EXPLICIT to predict the chip morphology under dynamic cutting conditions. Later, combines the elasticity of a classical high speed milling spindle system (tool, tool-holder and rotor) with the mesoscopic level chip formation process. A qualitative parametric study with various stiffness and damping coefficient values for high speed milling spindle system shows that, a less rigid un-damped milling system generates higher amplitude tool vibrations during cutting. In this situation, the temperature rises at tool-workpiece interface, enhancing material softening. Present study deals with the consequences of this softening on affecting the chip morphology (evolution of segmented chip morphology), and machined surface integrity. Further, numerical simulation results depict that the higher values of cutting speed and uncut chip thickness are associated with higher values of milling cutter vibration amplitudes.