Mechanics and Dynamics of Serrated End Mills

Abstract

Mechanics and dynamics of serrated milling cutters are presented in the article. The serrated flute design knots are fitted to a cubic spline, which is then projected on helical flutes. Cutting edge geometry at any point along the serrated flute is represented by its immersion angle and tangent vectors in radial, tangential and helix directions. The chip thickness removed by each cutting edge point is determined by using previously proposed exact kinematics of dynamic milling. The cutting forces are evaluated by orthogonal to oblique cutting mechanics transformation. The experimentally proven model is able to predict the cutting forces and chatter stability lobes in time domain.