Computer - Aided Optimal Design and Finite Element Analysis of a Plain Milling Cutter

Abstract: Plain Milling is one of the progressive enhancements of miniaturized technologies which have wide range of application in industries and other related areas. Plain milling cutters are widely used in roughing and finishing of parts. The milling cutter geometry and distribution of inserts on the cutter body vary significantly in industry depending on the application. This paper presents a generalized mathematical model of plain milling cutter for the purpose of predicting cutting forces, dimensional surface finish, stress, and strain. A sample of plain milling cutter modeling and analysis examples are obtained by using the design and analysis is carried out using the software’s like CATIA V5 and ANSYS. Milling like any metal cutting operation is used with an objective of optimizing surface roughness at micro level and economic performance at macro level. In addition to surface finish, modern manufacturers do not want any compromise on the achievement of high quality, dimensional accuracy, high production rate, minimum wear on the cutting tools, cost saving and increase of the performance of the product with minimum environmental hazards. In this Paper the design aspects of plain milling cutter is analyzed. The objective considered is the design and modeling of plain milling cutter and to analyse various stress components acting on it. Various designing strategies are considered to design the effective plain milling cutter like outer diameter, inner diameter, radius, teeth angle etc.