Simulation of static and dynamic shear forces and vibrations for used milling ceramic tools

Shear tools with ceramic inserts are increasingly used in the machining of super alloys commonly used in the aerospace industry. Ceramic inserts produce higher cutting speeds due to higher thermal resistance compared to carbide inserts. But the success of this process is very sensitive to the correct choice of process parameters. In this study, analytical process models for attachment milling tools with round ceramic inserts are presented. These models can be used to determine shear parameters for optimal quality and maximum efficiency. First, the geometry of the implant shear margins was formulated under the effect of angles on the implants. An analytical shear force model was then developed. This allows the analysis of the effects of parameters on shear forces. A field time model has also been developed to analyze the dynamic shear forces and static limits for the milling process. After that, the models were implemented in the MATLAB GUI to facilitate the applications of the model in the industry. The shear correlation coefficients required to calculate the shear forces were identified from shear tests with Inconel718. Then the shear force model was validated with shear experiences. After obtaining the instrument model data through pulse test, the forces and dynamic shear vibrations were simulated by the time domain model. A series of simulations were performed to determine the static limits in some operating conditions using the time domain model and static edges were drawn for the tool under study.