Simulations of chip formulation mechanism and phenomenon ccurred in cutting processes can help to reduce time and cost comparing with experiment. Finite element method (FEM) is an effective and accurate technique, which can be used for simulation of cutting process. In this paper, chip formulation process in high-speed milling of A6061 aluminium alloy is investigated using FEM based on the Johnson-Cook (J-C) and Bao-Wierzbicki (B-W) fracture models. The Von-Mises stress distribution and equivalent plastic strain (PEEQ) during cutting are then investigated. Finally, the evolution of cutting forces in cutting was examined. The presented Finite element model in this study proved to be useful in determination of cutting parameters, especially in high-speed machining.

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This paper presents experimental studied results about surface roughness during end milling SKD11 steel under room temperature and work-piece preheated condition. Conventional samples were first performed. The samples which are same technical parameters were then performed at elevated temperatures to evaluate effective of heating process on the surface roughness. Orthogonal array Taguchi method was used to experimental design. The results showed that the surface quality of product was significantly improved under thermal - assisted milling. The surface roughness model during machining at room and elevated temperatures were evaluated and showed a good agreement with result of experiments.