TECHNOLOGICAL ENGINEERING

volume XI, number 2/2014

ISSN 1336 - 5967
DOI: 10.2478/teen-2014-0014

SIMULATION COMPARISON STUDIES OF STRESS

AND DEFORMATION STATES OF A MILLING HEAD BY SYNCHRONOUS AND CONVENTIONAL MILLING
Article history:
Received 14 october 2014
Accepted 15 december 2014
Available online

Czeslaw Nizankowski, Tadeusz Otko, Pawel Piechnik

Krakow University of Technology, Mechanical Faculty, Department
of Technology Engineering and Production

Abstract
In the article, there were processed the results of
simulation-comparison studies of stress and deformation
states of a polymetallic, 5-edge milling head CoroMill
290, of company Sandvick Coromant, in the synchronous
and conventional milling of steel surfaces with various
cutting depths.
Keywords
synchronous and conventional milling, milling head,
stress- and deformation states
1 INTRODUCTION
A milling of flat surfaces can be realized with
synchronous and non-synchronous milling kine-matics.
The variants of the first kinematic circumferential speed
vector of the cutter is congruent with the feed vector
wherein the second version, it is opposite. These
differences were shown in the figure 1a and 1b.
a)

it takes a smaller load of the lead screw of the

milling machine, which is really the most important
part of the machine,
it results to the flattening of the workpiece to the
worktable of the milling machine which in turn
results in the application of low clamping values of
the workpiece in the clamping device.

The synchronous milling is is preferred not always.

This is occuring, when the surface of the workpiece is
hardened by the machining,for example, or contaminated by sand. An application of the conventional milling
with this conditions leads to lower cutting edges wear
substantially [3].
During the measurements of the temperature and
cutting forces in the deformation zone, the measurement
values are relatively easily accessible, the determination
of stress and deformation states of a milling head during
milling is very difficult, expensive and sometimes even
impossible.
Therefore, a sample was made to carry out a
simulation comparative studies of stress and deformation states of a milling head when synchronous and
conventional milling. These investigations were carried
out with the use of a module of the CosmosModule of
SolidWorks [4,6,7].
2 DESCRIPTION OF THE SIMULATION ANALYSIS
Beforethe determination of actual simulation model
of milling a following conditions was taken::

b)

Figure 1 Principle of synchronous milling (a) and

conventional milling (b). [1]
In the present, in the critical industrial applications,
there dominates the climb milling. It results from the
advantages of the milling method in comparison with the
conventional milling, namely:

there is missing the touch of the cutting edge on the

work piece material and it results to the smaller
wearing of the milling cutting edges and low
roughness values of the machined surfaces,

milling will be performed with the use of a milling

head type CoroMill 290 with 5 cutting edges, with
outer diameter 63 mm, diameter of the clamping
hole 22mm, height 40 mm, made with the body of
alloy steel 40HGM, (Figure 2),
Milling head is equipped with the cutting inserts
from the carbide S25 shims of material Ti-8mA, and
mounting screws from the carbon steel,
the workpiece is designed from the higher quality
class 40 of structural steel and has a shape of a
cuboid with the dimensions of 20x45x85 mm
(Figure 3). Cutting depth ap is given by 3 different
levels namely: 4, 8 and 10 mm, with constant
cutting speed vc = 250 m / min and feed on
onecutting edge fz = 0.05 mm and fz = 0.22mm
(worked for 2 at the same time cutting )

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Forces of cutting and their components are executed

by the well-known empirical formulas in the form of the
product ratios of the fundamental values of the process
that have been potentiated

Figure 6 strain distribution in the milling head 4mm in

depth of cut [1]

Figure 2 View of the milling head, type CoroMill 290 [1, 2, 5]

Figure 7 Stress distribution in the milling head at the

depth of 10 mm [1]

Figure 3 View of the workpiece [1]

Maximum temperature values on the cutting board

of two operating simultaneously cutting the cutter
head will be in accordance with 1000k and 700K,
the attachment of the milling head will follow in the
cutting zone and the stress and elastic deformations of the milling head will be analysed in a
short time periods to assume that the milling head
is stationary as compared to the workpiece. (Figure
4).

Figure 8 strain distribution in the milling head at the

depth of 10 mm [1]
synchronous milling

Figure 9 Stress distribution in the milling head 4mm

in depth of cut [1]
Figure 4 View of the milling head complex with the
attachment and insertion site forces [1, 4]
3 RESULTS OF SIMULATION STUDIES
Based on the simulation studies, selected distributions of stress and elastic deformations of the milling
head for the conventional milling are shown on Figures 5,
6, 7, and 8 and for the climb milling were shown on
Figures 9, 10, 11 and 12.
conventional milling

Figure 5 Stress distribution in the milling head in the

depth of 4mm entered with temperature [1]
18

Figure 10 strain distribution in the milling head 4mm

in depth of cut [1]

Figure 11 Stress distribution in the milling head in the

depth of 10mm with inputted temperature [1]

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Figure 12 strain distribution in the milling head in the

depth of 10mm with inputted temperature [1]
Figure 16 Change of stress in the milling head in dependence on the depth of the conventional milling; red entered with temperature, blue - without-entered
temperature [1]
4 CONCLUSIONS
The results of performed simulation studies allow to
execute the following conclusions:

Figure 13 Change of stress in the milling head in dependence on the depth of the synchronous milling; red entered with temperature, blue - without-entered
temperature [1]

maximum stress values in the milling head in the

synchronous milling are larger than in
conventional milling, and their values increase
almost linearly with the increasing depth of cut for
two analyzed types of milling,

maximal values of deformations in the milling

head in the synchronous milling are also larger
than in conventional milling with milling depth of
10 mm, the deformations are almost three times
lower than the climb milling with the conventional
milling. This phenomenon still require deeper,
merit analysis. The probable cause will be the
formation of small, plastic deformations in
(surface) [m2] net of the cutting insert.

References
[1]
Figure 14 Change in deformation the milling head in
dependence on the depth of the climb milling; red entered with temperature, blue - without-entered
temperature [1]

[2]

[3]
[4]
[5]
[6]

[7]

Piechnik P. Symulacja numeryczna mechanicznego

i termicznego obciazenia glowicy frezowej w
procesie frezowania wspolbieznego i przeciwbieznego. Praca dyplomowa PK, Krakow 2008 (Cz.
Nizankowski)
Sandvick Coromant Katalog Narzedzia
skrawajace do metali narzedzia obrotowe,
Warszawa 2006
Olszak W., Obrobka skrawaniem. ENT, Warszawa
2008
Babiuch M., Soliworks 2006 w praktyce.
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Zbala, w. Matras, A.: Aspects of fibre composite
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ajgalk, M. Czn, A: studying of processes in
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Technological engineering, 2011/2, pp. 10-12.

Figure 15 Change of stress in the milling head in dependence on the depth of the conventional milling; red entered with temperature, blue - without-entered
temperature [1]

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