Simulation of Milling Process in Roughening of Compressor Blade in Air Engine by Use of Finite Element Analysis

In high speed milling, prediction of cutting forces is of prime importance for optimum selection of end mill and machine tools. Since, machining of short blades can be performed only using a roughing and a finishing operation, increasing the machining efficiency during roughing and semi finishing is significant. In roughing process, removing the chips is an important factor, in which, by simulating the milling process, suitable cutting condition before performing the machining process. In this research, at first, Instantaneous chip geometry was estimated using a 3D simulation software. Then, the cutting force coefficients were determined using the full immersion milling tests and the mass, stiffness and damping matrices are obtained using the finite element analysis. Finally, modeling and dynamic simulation of the cutting forces are performed and the effect of the depth of cut is determined and cutting conditions are predicted before doing the machining process. The simulation results are investigated and validated using the experimental results.