Mathematical modelling and numerical simulation of forces in milling process

Machining of the material by milling induces forces, which act on the work piece material, tool and which in turn act on the machining tool. The forces involved in milling process can be quantified, mathematical models help to predict these forces. A lot of research has been carried out in this area in the past few decades. The current research aims at developing a mathematical model to predict forces at different levels which arise machining of Aluminium6061 alloy. Finite element analysis was used to develop a FE model to predict the cutting forces. Simulation was done for varying cutting conditions. Different experiments was designed using Taguchi method. A L9 orthogonal array was designed and the output was measure for the different experiments. The same was used to develop the mathematical model.