Q2. What is the experimental device used to obtain cutting forces curves?
The experimental device used to obtain experimental curves is based on a Kistler dynamometer using piezoelectric accelerometers technology.
Q3. Why was a simplified model used in milling?
Due to the complex geometry of the tools, a simplified model was used in calculation to reproduce accurately the helix and the rake angles only.
Q4. What are the main reasons why an explicit scheme is useful?
An explicit scheme is quite useful in the case of high non linearities associated tomaterial behaviour, contact interface, friction law and high mesh distorsion.
Q5. What is the criterion for a proper chip formation in milling?
Von Mises stress contours in shoulder milling (down milling configuration, two tooth pathes)The failure criterion and the introduced mesh permit to obtain a proper chip formation in milling.
Q6. What are the experimental conditions used to test cutting forces?
During the experimental investigations of milling, high speed milling and micro-milling, numerous cutting conditions were tested.
Q7. What are the main reasons why the set up of robust simulations is easier?
In spite of the conditional stability of the explicit time integration scheme, the set upof robust simulations is easier than with implicit time integration scheme.
Q8. What is the main reason why the cutting forces curves are not accounted for in the academic?
The FEM cutting forces curves, in the academic conditions, present coherent and predictive values in relation with the experimental cutting forces, even with simplifying assumptions.
Q9. What is the appropriate method to model the investigated phenomena?
Even if the arbitrary Lagrangian-Eulerian description seems to be the most appropriate method to model the investigated phenomena (high strain gradients, localisation phenomena, mesh separations,chip geometry and flow), this method is not retained here.
Q10. How long is the computation time on a LS-DYNA cluster?
This computation time is about 6 days on a cluster equiped with 8 processors 3,2 GHz with 64Go RAM with a MMP version of LS-DYNA.