Design of tools with the cutting part of the original profile for high-speed milling

Abstract

This paper considers and justifies the design of the cutting part of multi-edge contour mills with the increased performance and surface quality. The numerical experiments using the finite element method (FEM) allow determining stresses and deformations in the layer of the material being cut when processed by multi-edge mills of a new type, i.e. they allow evaluating indirectly unit loads during milling. The required shape and dimensions of the cutting wedge were determined taking into account various values of the geometric parameters of the cutting part, the properties of the workpiece material and cutting conditions. All the above resulted in a 3D model of the end mill, which had got a trapeze-shaped tooth located along two intersecting helical lines with tilt angles of 22 and 85 degrees. Along with improving the quality of the processed surface, the experimental studies also showed a change of chip shape. The chip has a finely crushed structure; the sizes of its elements are about 2 μm, which agrees nicely with the results of the FEM preliminary estimates.