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In order to investigate the thermo-mechanical coupling of the end milling cutter during high speed end milling and search for the failure mechanism, based on reverse engineering, the geometric model of the end milling cutter and workpiece was established. To simulate the end-mill cutting, a 3D thermo-mechanical coupling model was proposed using ABAQUS. Through the thermo-mechanical coupling analysis, it was found that the temperature of the milling cutter was gradually decreased around the tip, and the maximum temperature of the tip was about 904°C. Cutting temperature field, chip formation, and cutting forces were well predicted by the 3D FE models proposed herein embedded with the thermo-mechanical coupling model. The simulation results agree with the experimental data, indicating that the 3-D thermo-mechanical coupling model is effective for predicting the stress field and temperature field, and it can serve as a reference for end-mill wear analysis.
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