Analytical study on the cutting force and residual stress in whirlwind milling of a large screw

The finite element method (FEM) is developed to simulate a discontinuous cutting in the whirlwind milling. Firstly, a simplified arc-cutting model for simulating the actual circular cutting, and a plane-cutting model for simplification were both developed and verified by experiments. Then, the effects of cutting parameters on the cutting force and residual stress were effectively investigated based on the plane-cutting model. Moreover, a plane-second- -cutting model was further developed. It showed that a minor decrease of cutting force and a higher maximum compressive stress were generated in the second cutting. Those results were conducive to predict and improve the whirlwind milling.