Article: Optimisation of tool angles and the relation between tool path and cutting force in high-speed milling with micro-end-mill Journal: International Journal of Computer Applications in Technology (IJCAT) 2007 Vol.28 No.1 pp.20 - 26 Abstract: On the basis of high-speed milling experiments of hardened steel, two technical problems associated with micro-end-mill tools have been investigated in this paper. The optimisation of tool angles was discussed firstly. Cutting force, cutting vibration and tool wear areas of different tool rake angle γο, frank angle αο and helix angle β are recorded and analysed, and recommended tool angles are proposed. The milling process will be steady with negative rake angle, except that the tool wear is little severe. Longer life will be obtained with small positive rake angle about 0–5° in the high-speed milling of hardened steel. It is appropriate to adopt the clearance angle as high as 15°. The helix angle can be designed as 0° for longer tool life or 30° for integrated performance. The changes of cutting force under different tool paths have also been analysed. The cutting forces of side milling and slot milling with the same material removal rate are compared. Milling experiments of different line corners have also been completed and the changes of cutting force are analysed. It can be concluded that cutting force is not only decided by material removal rate in high-speed milling with micro-end-mill. The direction of feedrate and the feed system of the worktable machine tool need to be paid attention to. Inderscience Publishers - linking academia, business and industry through research

Title: Optimisation of tool angles and the relation between tool path and cutting force in high-speed milling with micro-end-mill

Authors: Zhe Qin, Chengyong Wang, Yisong Lin, Yinning Hu

Addresses: Institute of Manufacturing Technology, Guangdong University of Technology, Guangzhou 510090, PR China. ' Institute of Manufacturing Technology, Guangdong University of Technology, Guangzhou 510090, PR China. ' GSK CNC Equipment Co., Ltd, Guangzhou 510165, PR China. ' Guangxi University, Nanning, 530004, PR China

Abstract: On the basis of high-speed milling experiments of hardened steel, two technical problems associated with micro-end-mill tools have been investigated in this paper. The optimisation of tool angles was discussed firstly. Cutting force, cutting vibration and tool wear areas of different tool rake angle γ_ο, frank angle α_ο and helix angle β are recorded and analysed, and recommended tool angles are proposed. The milling process will be steady with negative rake angle, except that the tool wear is little severe. Longer life will be obtained with small positive rake angle about 0–5° in the high-speed milling of hardened steel. It is appropriate to adopt the clearance angle as high as 15°. The helix angle can be designed as 0° for longer tool life or 30° for integrated performance. The changes of cutting force under different tool paths have also been analysed. The cutting forces of side milling and slot milling with the same material removal rate are compared. Milling experiments of different line corners have also been completed and the changes of cutting force are analysed. It can be concluded that cutting force is not only decided by material removal rate in high-speed milling with micro-end-mill. The direction of feedrate and the feed system of the worktable machine tool need to be paid attention to.

Keywords: high-speed milling; hardened steel; micro-end-mills; tool angles; tool paths; cutting forces.

DOI: 10.1504/IJCAT.2007.012327

International Journal of Computer Applications in Technology, 2007 Vol.28 No.1, pp.20 - 26

Published online: 06 Feb 2007 *

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Title: Optimisation of tool angles and the relation between tool path and cutting force in high-speed milling with micro-end-mill

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