Numerical Investigation of the Stress–Strain and Thermal Response of a Mushroom-Shaped Slot Milling Cutter Under Different Cutting Forces

Milling cutters are subjected to variable mechanical loads during machining, which can affect their structural integrity and thermal condition. This study aims to evaluate the effect of external cutting force on the stress–strain and thermal responses of a mushroom-shaped slot milling cutter. A three-dimensional model of a six-tooth cutter with a 14 mm cutting diameter and an 8 mm shank diameter was developed in SolidWorks Simulation. The cutter was modeled using AISI M2 high-speed steel, while an AISI 4340 steel workpiece was included to represent the cutter–workpiece contact. Static analyses were performed under forces of 500, 750, and 1000 N, and the von Mises stress, resultant displacement, and equivalent strain were determined. Thermal analyses were additionally conducted using corresponding heat inputs. The maximum von Mises stresses were 158.8, 238.4, and 326.9 MPa, while the corresponding displacements were 0.04529, 0.05818, and 0.09097 mm for 500, 750, and 1000 N, respectively. The maximum temperatures increased from 380.15 to 561.95 and 748.85 °C with increasing load. The results demonstrate a systematic increase in both mechanical and thermal responses with increasing cutting force, providing a basis for identifying critical regions and assessing cutter operating conditions.