Three Dimensional Finite Element Simulation of Cutting Forces and Cutting Temperature in Hard Milling of AISI H13 Steel

Compared with the traditional technological process, hard milling of hot work tool steel (AISI H13) can significantly improve the physical/mechanical performances of machined components. A three dimensional (3D) finite element (FE) simulation model was built in this research to investigate the complex nonlinear process. First, the geometric model of workpiece was established considering the previous machined surface profile in actual milling process. Secondly, the prediction validation of the simulation model about hard milling process was verified by comparing the simulated cutting forces with the experiment results. Finally, the effect of cutting speed and feed rate on cutting forces and cutting temperature were researched by using the FE simulation model. The results indicate that cutting forces increase with the increase of feed rate, while cutting temperature increases with the increase of cutting speed. The effects of cutting speed on cutting forces and feed rate on cutting temperature are not significant. The simulated temperature is much lower than the austenitizing temperature of AISI H13 steel which means white layer is unlikely to be formed under the cutting conditions used in this study. The research can contribute to the fundamental understanding of mechanism and optimization of cutting parameters in hard milling.