Prediction Of Limit Rotational Speeds In A High-Speed Tool Bason FE Computed J-Integral Intensitiesed

In order to obtain an estimate of the critical number of rotations for a high speed milling tool crack growth analysis has been performed. The crack growth is determined from stress intensities computed by J-integrals. The problem is solved in 3D using ANSYS. Boundary conditions arising from a contact pressure caused by a conical coupling are computed by contact elements allowing for both friction and plasticity and comparison with strain gauge measurements shows good agreement. The complex load configuration involves dynamical effects such as inertia and cutting force, and non-linear FEM analysis has been performed in ANSYS. The result of the analysis is a number of stress intensity factors for each load case, i.e. six load cases. These are superposed to obtain stress intensity factors for combined load cases. The estimates of the critical rotational speed provided by this method has proven to be applicable for the industrial partner, and less conservative compared to estimates determined from the code of practice.