Print Email Facebook Twitter Design of micro square endmills for hard milling applications Title Design of micro square endmills for hard milling applications Author Li, P. Oosterling, J.A.J. Hoogstrate, A.M. Langen, H.H. Munnig Schmidt, R.H. Faculty Mechanical, Maritime and Materials Engineering Department Precision and Microsystems Engineering Date 2011-04-20 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. Subject micro hard millingendmill designmodellingtool wear To reference this document use: http://resolver.tudelft.nl/uuid:2db85a10-7d8a-4c93-b542-9051a5dd82f3 DOI https://doi.org/10.1007/s00170-011-3330-6 Publisher Springer Verlag ISSN 1433-3015 Source International Journal of Advanced Manufacturing Technology, 2011 Part of collection Institutional Repository Document type journal article Rights (c) 2011 The Author(s). This article is published with open access at Springerlink.com Files PDF li2011.pdf 1015.13 KB Close viewer /islandora/object/uuid:2db85a10-7d8a-4c93-b542-9051a5dd82f3/datastream/OBJ/view