Finite element simulation analysis in helical milling of countersunk hole

A large number of countersunk holes need to be machined during the assembly of aerospace components. The widespread use of difficult-to-cut materials has brought new challenges to the hole-making technology. As a new hole-making technology of assembly, helical milling can be used to machine countersunk holes with special tools, and the machining quality can be improved by using the characteristics of helical milling principle. Firstly, the kinematics analysis of helical milling in machining countersunk holes was carried out. Next, finite element simulation was used to simulate the helical milling process of countersunk holes in titanium alloy materials. Then, the accuracy of the finite element simulation was verified through the cutting force and chip morphology in helical milling test. Finally, the established simulation model was used to analyze the influence of dimple depth and process parameters on the cutting force acting on the cutting tool.