Mechanics and Dynamics of Serrated Cylindrical and Tapered End Mills

[+] Author and Article Information
S. D. Merdol, Y. Altintas

Manufacturing Automation Laboratory, University of British Columbia, 2324 Main Mall, Vancouver, BC Canada, V6T 1Z4 http://www.mech.ubc.ca/∼mal

J. Manuf. Sci. Eng 126(2), 317-326 (Jul 08, 2004) (10 pages) doi:10.1115/1.1644552 History: Received August 01, 2002; Revised October 01, 2003; Online July 08, 2004
Copyright © 2004 by ASME
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(a) Serrated cylindrical cutter geometry (b) angle definitions (c) spline fitting
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Mathematically modeled serrated cutter
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Serrated tapered ball end mill
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Vector definitions for tapered cutters
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Sample serration profiles of consecutive teeth
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(a) Milling operation (b) general milling force diagram (c) direction convention (d) force diagram, chip thickness
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Half immersion down milling with 3 fluted cylindrical end mill at 1600 rpm (a) 8 mm axial depth of cut and 0.08 mm/rev.tooth feed rate (b) 8 mm axial depth of cut, 0.10 mm/rev.tooth feed rate (see Table 1)
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Half immersion up milling with 3 fluted cylindrical end mill at 1600 rpm (a) 4 mm axial depth of cut and 0.08 mm/rev.tooth feed rate (b) 6 mm axial depth of cut, 0.08 mm/rev.tooth feed rate (see Table 1)
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Full immersion milling with tapered ballend mill, 15 mm depth of cut and 0.04 mm/rev.tooth at 1000 rpm (see Table 1)
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Chip thickness distributions for 3 fluted cylindrical regular and serrated endmills, c=0.04 mm/rev.tooth, full immersion, (a) regular endmill, distribution at all axial levels (b) serrated cutter, distribution at the tool tip (c) serrated cutter, distribution at z=1.2 mm
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Measured and simulated stability lobes for 3 fluted cylindrical serrated endmill, material: Al 7050, c=0.04 mm/rev.tooth, full immersion, experimental results, see Table 1
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Simulated cutting forces: 3 fluted cylindrical helical endmill, 5000 rpm, 0.05 mm/tooth.rev, 10 mm depth of cut



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