FE simulation model of high-speed rail milling

This research extends the application of an Arbitrary Lagrangian-Eulerian (ALE)-based finite element simulation model specifically designed to analyze high-speed milling processes in rail milling, emphasizing the dynamics of chip formation and the stress and temperature distributions within the milled workpiece. The study primarily investigates milling operations at two cutting speeds: 240 m/min, where results are validated against experimental data, and 380 m/min, which offers new insights into the material behavior under high-speed milling conditions. The evaluation critically assesses the capability of the model in predicting material flow, residual stress fields and heat distribution, aligning these predictions with experimental observations. The findings demonstrate the robustness of the numerical model in simulating complex physical phenomena specific to high-speed milling.