Simulation-Based Analysis and Intuitive Visualization of the Cutting Edge Load in Micromilling of Hardened Steel

The precise micromanufacturing of complex dies with small structures for sheet-bulk metal forming is a challenge due to the high hardness of the materials to be machined. Experiments have shown that micromilling of these difficult-to-machine materials is possible despite of their high hardness. Nevertheless, the higher wear of the tools plays a decisive role. When implementing the machining task as five-axis process, it is possible to control the wear distribution by tilting the milling tools. In this paper, a simulation system is presented which determines the loads acting on the cutting edge with regard to different criteria, e.g., the machined material or the effective impulse. Based on this knowledge, it is possible to design the milling process to minimize the tool wear and thereby to increase the lifetime of the milling tools. In order to show the applicability of the simulation system, test workpieces were machined and the experimental results are compared to the simulation data.