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TECHNICAL PAPERS

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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References

Ehmann,  K. F., Kapoor,  S. G., DeVor,  R. E., and Lazoglu,  I., 1997, “Machining Process Modeling: A Review,” ASME J. Manuf. Sci. Eng., 119, pp. 655–663.
Tlusty, J., Ismail, F., and Zaton, W., 1982, “Milling Cutters With Irregular Pitch,” Technical Report, McMaster Engineering.
Campomanes, M. L., 2002, “Kinematics and Dynamics of Milling With Roughing Endmills,” Metal Cutting and High Speed Machining, Kluwer Academic/Plenum Publishers.
Altintas, Y., 2000, Manufacturing Automation, Cambridge University Press.
Sutherland,  J. W., and DeVor,  R. E., 1986, “An Improved Method for Cutting Force and Surface Error Prediction in Flexible End Milling Systems,” ASME J. Eng. Ind., 108, pp. 269–279.
Altintas,  Y., and Lee,  P., 1996, “Prediction of Ball End Milling Forces From Orthogonal Cutting Data,” Int. J. Mach. Tools Manuf., 36(9), pp. 1059–1072.
Altintas, Y., Engin, S., and Budak, E., 1998, “Analytical Prediction of Chatter Stability and Design for Variable Pitch Cutters,” IMECE Manufacturing Science and Engineering, MED Vol. 8, pp. 141–148, Anaheim, CA.
Onwubiko, C., 1989, Foundations of Computer-Aided Design, West Publishing, MN.
Altintas,  Y., and Lee,  P., 1998, “Mechanics and Dynamics of Ball End Milling,” ASME J. Manuf. Sci. Eng., 120, pp. 684–692.
Ramaraj,  T. C., and Eleftheriou,  E., 1994, “Analysis of the Mechanics of Machining With Tapered End Milling Cutters,” ASME J. Eng. Ind., 116, pp. 398–404.
Engin,  S., 2001, “Mechanics and Dynamics of Genereal Milling Cutters, Part I: Helical End Mills,” Int. J. Mach. Tools Manuf., 41, pp. 2195–2212.
Zeid, I., 1991, CAD/CAM Theory and Practice, McGraw-Hill Inc.
Budak,  E., Altintas,  Y., and Armarego,  E. J., 1996, “Prediction of Milling Force Coefficients From Orthogonal Cutting Data,” ASME J. Eng. Ind., 118, pp. 216–224.
Stabler, G. V., 1964, “The Chip Flow Law and Its Consequences,” Advances in Machine Tool Design and Research, pp. 243–251.
Montgomery,  D., and Altintas,  Y., 1991, “Mechanism of Cutting Force and Surface Generation in Dynamic Milling,” ASME J. Eng. Ind., 113, pp. 160–168.
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Figures

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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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