Validation of a Heat Input Model for the Prediction of Thermomechanical Deformations during NC Milling

During roughing in NC milling, heat is introduced into the workpiece. For the manufacturing of large structural components, a constantly changing temperature field is created due to the rapid movement and the varying contact conditions between tool and workpiece. Therefore, significant deformations can cause form errors that lead to rejects in the production process. In this paper, a simulation system for the prediction of transient workpiece temperatures is presented. In order to calibrate the system, simple experiments have been conducted, and a model for the introduction of energy into the workpiece via cutting has been developed. The newly developed cutting-energy input model makes it possible to perform fast simulations. Therefore, it can be used to perform simulations of the thermoelastic workpiece deformations during milling of complex shaped parts.