Analysis of milling chatter stability and experimental study on cutting performance with discrete-edge end milling cutters

Abstract

Abstract Discrete-edge end milling cutters are a new type of tool that regularly grinds a certain number of chip breaking grooves on the circumferential edge. The original cutting state is changed due to the presence of chip breaking grooves. In order to further explore the milling performance of the type of tools, discrete-edge end milling cutters with chip breaking grooves are designed and simulated by using NUM software. Then, they are processed and ground by using SAACKE five axis grinding machine. Orthogonal milling experiments were established using aluminum alloy samples as the processing object and an end milling cutter of the same specification without chip breaking grooves as a control group. Combined with modal parameter identification experiments and milling force coefficient experimental data, time-domain analysis was used to solve the stability of the milling system and blade diagrams were drawn. In addition, vibration signals, milling forces and chip shapes were analyzed. The results show that the minimum limit axial cutting depth of the discrete-edge end milling cutters are about 20% higher than that of the conventional end milling cutter within the same radial cutting width and calculated spindle speed. It shows that the milling stable area of the discrete-edge end milling cutters are larger and have a wider scope of application. At the same time, due to the existence of the chip breaker, it can effectively break chips and facilitate chips removal.