milling tool

Powerful Essays
Topics: Wear, Machining, Cutting
Int J Adv Manuf Technol (2011) 57:859–870
DOI 10.1007/s00170-011-3330-6

ORIGINAL ARTICLE

Design of micro square endmills for hard milling applications
Peiyuan Li & J. A. J. Oosterling & A. M. Hoogstrate &
H. H. Langen & R. H. Munnig Schmidt

Received: 10 November 2010 / Accepted: 5 April 2011 / Published online: 20 April 2011
# The Author(s) 2011. This article is published with open access at Springerlink.com

Abstract In experiments of machining hardened tool steels
(such as AISI H11, H13, and D2, up to 56 HRC) by commercial Ø 0.5 mm square endmills, it is observed that the tested micro endmills showed severe wear at an early stage of the process due to chipping off around cutting edge corners, resulting in unsatisfactory tool life and product appearance (burr formation). Detailed examination of current tool geometry shows that it is mainly inherited from that of macro endmills, making the cutting edge corners the weakest part on the tool. As the micromilling process is characterized by small values of machining parameters, the cutting edge corners of the micro endmill are the most loaded part of the cutting edges. New design rules are studied for improving the stiffness and strength of micro endmills used in micro hard milling applications.
Analytical modelling and finite element method analysis are used to aid the design of tool geometry. By using a larger neck angle, optimizing tool core geometry, and choosing a negative rake angle, tool stiffness and cutting edge strength are improved. The new endmill designs, both two-flute and four-flute, are tested in experiments on hardened tool steels and showed considerable lower tool wear and increased tool life. Furthermore, the geometrical accuracy and appearance of the workpiece (burr formation) has been improved drastically.
P. Li (*) : H. H. Langen : R. H. Munnig Schmidt
Department of Precision and Microsystems Engineering,
Delft University of Technology,
Mekelweg 2,
2628CD Delft, The Netherlands
e-mail:



References: 1. Bissacco G, Hansen HN, De Chiffre L (2006) Size effects on surface generation in micro milling of hardened tool steel 4. Bao WY, Tansel IN (2000) Modeling micro-end-milling operations. 7. Filiz S, Conley CM, Wasserman MB, Ozdoganlar OB (2007) An experimental investigation of micro-machinability of copper 101 8. Rahman M, Kumar AS, Prakash JRS (2001) Micro milling of pure copper 9. Uriarte L, Herrero A, Zatarain M, Santiso G, Lopéz de Lachalle LN, Lamikiz A, Albizuri J (2007) Error budget and stiffness chain 10. Takács M, Verö B, Mészáros I (2003) Micromilling of metallic materials 13. Dimov SS, Pham DT, Ivanov A, Popov K (2005) Micromilling of thin features 14. Dow TA, Miller EL, Garrard K (2004) Tool force and deflection compensation for small milling tools Sánchez JA (2005) Evaluation of the stiffness chain on the deflection of end-mills under cutting forces Manuf 45:727–739 Int J Adv Manuf Technol (2011) 57:859–870 16. Schmidt J, Tritschler H, Haberer H (2001) Cutting tools and material conditioning for micro end milling of tool steel 17. Uhlmann E, Schauer K (2005) Dynamic load and strain analysis for the optimization of micro end mills 18. Fang FZ, Wu H, Liu XD, Liu YC, Ng ST (2003) Tool geometry study in micromachining 19. Adams DP, Vasile MJ, Benavides G, Campbell AN (2001) Micromilling of metal alloys with focused ion beam-fabricated 21. Tlusty G (2000) Manufacturing processes and equipment.

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