Optimizing Milling Processes through FEA: An In-depth Analysis of Cutting Tool Geometric Parameters and Their Impact on Performance of milling.

Abstract In the rapidly advancing world of manufacturing, the optimization of cutting processes is of paramount importance for enhancing efficiency and product quality. This work underscores the necessity of employing Finite Element Analysis (FEM) for a comprehensive understanding and improvement of cutting processes. By leveraging DEFORM we create a detailed 2D simulation of the milling process, allowing for an unprecedented inspection of the procedure in a virtual environment. Central to our investigation is the variation of geometric parameters of the cutting tool within the FEM simulation model, offering insights into how minute alterations can significantly affect the outcome of the milling process. The study systematically analyzes the impact of the milling tool’s geometric parameters on various process parameters, including chip formation and cutting forces. This analysis is critical for identifying optimization opportunities in tool design and process settings. Furthermore, we delve into the stress-strain state of the cutting zone, a factor crucial for understanding the material behavior under operational conditions and ensuring the structural integrity of the final product. Through our findings, we demonstrate that strategic modifications in the geometric parameters of the cutting tool can lead to substantial improvements in process performance. This research not only contributes to the body of knowledge on milling processes but also provides practical recommendations for engineers and manufacturers striving to optimize their cutting operations through the application of FEM.