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Automobile panel moulds are assembled pieces with various surface features, making it difficult to predict the machining properties in ball-end milling process. In this paper, Deform 3D finite element analysis software is used to simulate the ball-end milling of multi-hardness assembled moulds, and to analyse the distribution patterns of milling forces, stress fields and temperature fields in the transition regions of the multi-hardness assembled moulds. Subsequently, milling of sine surface moulds is simulated, and the effects of milling parameters on the thermal performance of sine surfaces are analysed. Finally, the multi-hardness assembling and milling experiment and the sine surface mould milling experiments are conducted to verify the effectiveness of the Deform 3D finite element simulation method.

Prediction models for machining brittle and hard materials are barely seen while various prediction models for machining metallic materials such as cast iron and steel have been researched and developed in the past several decades. In this paper a new grinding force model is developed for machining brittle and hard materials such as Al 2 O 3 and SiC. By studying removal mechanism, and confirming the value of brittle-ductile transition of hard and brittle materials, equations for the total normal and tangential force components per unit width of the grinding process including three stages of plowing, cutting and rubbing are researched. The prediction model has finally been presented and discussed thoroughly.