Analysis of vibration assisted dry end milling using 3D FE simulation – An investigational approach

Abstract A three-dimensional finite element simulation model is developed to analyze the vibration-assisted dry end milling of Ti-6Al-4V alloy specimens. Results of finite element simulated forces in cutting and deflections of the cutter are compared experimented results. Cutting forces in the experiment are recorded using a Kistler 9272 force dynamometer and vibration signal data is acquired using a triaxialKistler (Model_8793) accelerometer. Two milling cutters, both uncoated and coated milling cutters are used for the experimental investigation. In the end, the impact of spindle rotational speed and feed rate on forces in cutting and subsequent tool deflections were also premeditated using the FE simulations. The investigation shows that there is a rise in forces of cutting as the feed is increasing and deflection also increases as the surge in feed rate and rotational speed. The experimental investigation will give the insights to understand the mechanics of the milling operation and thereby this data is cast-off to treasure the optimal machining conditions.