Stress state simulation of the radial end milling cutter at shaping the complex surfaces

The paper presents results of simulating stress state in the cutting edge zone of the radial end milling cutter with the given tool orientation along the transverse angle. Simulation involved calculating the cutting forces in the ABAQUS program, converting them into loads acting on the tool surface, determining the contact zone of the tool front surface with chips based on the cutting theory and calculating stresses with the uniform load distribution in the considered tool section. Results of the preliminary calculations are provided. Distribution curves of the equivalent, normal and shear stresses in the cutting edge zone of the radial end milling cutter obtained using hardware of the ANSYS finite element analysis system were constructed. Simulation results allow further research to study the tool orientation and the cutting conditions influence on the tool stress state in shaping the complex surfaces. Determination of the machined surface zones, where the calculated stress values exceed the critical values, using the model makes it possible already at the initial stage of the technological process development to exclude destruction of the tool cutting edges and to achieve maximum productivity in shaping the complex surfaces.