MECHANICS

Numerical modeling of the contact stress distribution in a cutting wedge during the milling of AISI 304 and Grade 5 alloys with a carbide conical end mill

P. M. Pivkin^a, A. S. Babaev^b, V. N. Kozlov^b, A. R. Semyonov^b, E. S. Nazarenko^a, A. B. Nadykto<sup>a

a</sup> Moscow State University of Technology STANKIN, Moscow, Russian Federation
^b Tomsk State University, Tomsk, Russian Federation

Abstract: This paper presents the results of the finite element modeling of the milling of AISI 304 SS stainless steel and Grade 5 titanium alloy. The mathematical formulation of the problem is outlined along with the assumptions and simplifications adopted to enable efficient computation. The results of the numerical simulations are reported, taking into account variations in the cutting conditions, including the cutting regimes and edge microgeometry. A multilevel model is proposed in which functional relations between the tool design parameters, cutting edge sharpness, cutting modes, characteristics of the processed material, and the arising equivalent von Mises stresses in the cutting wedge of the milling tooth are specified. The study results make it possible to obtain a cutting part with improved geometrical parameters of a new generation tool, to increase its rigidity and strength, and to improve the tool performance.

Keywords: numerical modeling of cutting, finite element method, milling, contact stresses, steel, titanium alloy.

UDC: 621.9.011; 004.942

Received: 21.04.2025
Accepted: September 6, 2025

DOI: 10.17223/19988621/97/10