Original Article Three-dimensional finite element modeling of effect on the cutting forces of rake angle and approach angle in milling Kadir Gok 1 , Hu ¨ seyin Sari 2 , Arif Gok 3 , Su ¨ leyman Neseli 4 , Erol Turkes 5 and Su ¨leyman Yaldiz 4 Abstract In this study, milling operations were carried out using AISI 1040 specimens steel in dry cutting conditions. The cutting tools used in the experiment include P20 tool steel and they also have three different approach angles (45  , 60  , 75  ) and rake angles (0  , 6  , 12  ). In milling experiments, cutting parameters with a depth of cut of 1.5 mm, cutting speed of 193 m/min, and feed rate of 313 mm/min were selected. A comparison was presented between the force values which were obtained by measured value and predicted with numerical simulations, and then a good agreement was found between measured and predicted force values. As result of, it was observed that the rake and approach angles were effective in milling operations. Keywords Metal cutting, finite element method, milling operations, rake angle, approach angle Date received: 21 August 2014; accepted: 16 February 2015 Introduction Milling operations are commonly used in the mech- anical industry. In the aeronautical sector, it repre- sents 70% of overall machining operations. 1 Milling operations have a complex structure due to variability of cutting parameters. Milling operations can be cal- culated by experimental, analytical, and finite element methods (FEM). Experimental methods have a lim- ited structure in terms of both cost and time. In order to calculate the milling operations analytically, you need to oversimplify them. Today, solving of these complex structures has become easier with the devel- opment of computers and software. Milling oper- ations are analyzed using programs developed based on FEM. During the milling operations, FEM can calculate the cutting tool stresses, cutting forces, cut- ting tool wear, temperature on the cutting tool, etc. Selecting correct cutting parameters and appropriate material can provide a good face quality and longer cutting tool life. There are various studies related to cutting analysis and effect of cutting geometry, which have rake and approach angle in the literature. Gu¨nay et al. 2 pre- sented a study of comparison of empirical and experi- mental results for main cutting force during machining rotational parts by unworn cutting tools. In Gu¨nay et al., 3 the influence of tool rake angle on main cutting force was investigated during machining of AISI 1040 material. Saffar et al. 4 presented a three- dimensional (3D) simulation system in order to pre- dict cutting forces and tool deflection during end- milling operation. In Pittala` and Monno, 1 3D FEM simulation was performed to predict cutting forces during face milling of an aluminum alloy. In Yang et al., 5 the temperature distribution of the micro- cutter in the micro-end-milling process was investi- gated with numerical simulations and experimental approach. In Ozel and Altan, 6,7 the analysis was car- ried out with a 2D FEM commercial code for flat end Proc IMechE Part E: J Process Mechanical Engineering 0(0) 1–6 ! IMechE 2015 Reprints and permissions: sagepub.co.uk/journalsPermissions.nav DOI: 10.1177/0954408915576698 uk.sagepub.com/jpme 1 Kutahya Vocational School of Technical Sciences, Dumlupinar University, Kutahya, Turkey 2 Ilgın Vocational School of Technical Sciences, Selcuk University, Ilgın, Konya, Turkey 3 Technology Faculty, Department of Mechanical Engineering, Amasya University, Amasya, Turkey 4 Technology Faculty, Department of Mechanical Engineering, Selcuk University, Konya, Turkey 5 Technology Faculty, Department of Mechatronics Engineering, Kırklareli University, Kırklareli, Turkey Corresponding author: Kadir Gok, Kutahya Vocational School of Technical Sciences, Dumlupinar University, Germiyan Campus, 43100 Kutahya, Turkey. Email: kadirgok67@hotmail.com by guest on March 20, 2015 pie.sagepub.com Downloaded from