A comparative analysis of ceramic and cemented carbide end mills

Dröder, Klaus; Karpuschewski, Bernhard; Uhlmann, Eckart; Arrabiyeh, Peter A.; Berger, Daniel; Busemann, Sarah; Hartig, Jörg; Madanchi, Nadine; Mahlfeld, Georg; Sommerfeld, Christian

doi:10.1007/s11740-020-00966-9

Cited by 17 publications

(9 citation statements)

References 12 publications

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“…As described in chapter 2, for the evaluation of the deep groove grinding, especially the chipping of the cutting edge is used to describe the process quality. [10]. Fig.…”

Section: ) Analyzes Of the Cutting Edge Qualitymentioning

confidence: 99%

“…The use of hybrid bond grinding wheels with a combination of a resin and a metallic bond allows the combination of high productivity and high surface qualities [8,9]. A cutting edge with less defects is important for the operational behavior of the end mill cutters [3,10]. This paper presents a knowledge-based model for reducing wear differences in ute grinding.…”

Section: ) Introductionmentioning

confidence: 99%

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Operational Behavior of Graded Diamond Grinding Wheels For End Mill Cutter Machining

Denkena

Bergmann

Raffalt

2021

Preprint

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The varying related material removal rate during deep grinding of cemented carbide end mill cutters results in an unevenly wear of the grinding wheel. This causes a reduced geometrical precision of the manufactured tools. Consequently, the intervals between dressing steps are reduced and the dressing infeed increases. The aim of this research project is therefore to design a tailored grinding tool with uniform wear behavior. To address this situation, the grinding tool load is determined simulatively along the width of the grinding wheel. From this an equation is derived to adapt the bonding layer properties to the local load differences. First investigations show that two different concentrations zones in the abrasive layer of the grinding wheel improves the wear behavior already. This indicates that a further reduction of the wear difference is possible by a more uniform gradient. A simulation is performed to define a knowledge based gradient with more than two concetration zones. This allows a more precise load optimized adaptation of the grinding layer properties to the geometry to be ground in terms of wear behavior. Grinding tools manufactured on this basis are used for flute grinding of end mill cutters. A reduction of the wear difference over the grindig wheel width of 52% and an improved cutting edge quality of these are demonstrated.

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“…As described in chapter 2, for the evaluation of the deep groove grinding, especially the chipping of the cutting edge is used to describe the process quality. [10]. Fig.…”

Section: ) Analyzes Of the Cutting Edge Qualitymentioning

confidence: 99%

Section: ) Introductionmentioning

confidence: 99%

Operational Behavior of Graded Diamond Grinding Wheels For End Mill Cutter Machining

Denkena

Bergmann

Raffalt

2021

Preprint

View full text Add to dashboard Cite

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“…Therefore, the grinding wheels exhibit a hybrid bond. A cutting edge with less defects is important for the operational behaviour of the end mill cutters [3,10]. This paper presents a knowledge-based model for reducing wear differences in flute grinding.…”

Section: List Of Symbolsmentioning

confidence: 99%

“…To be suitable for industrial use, the graded grinding tools must prove that they do not reduce the workpiece quality, such as the cutting edge rounding, or the roughness of the rake face or flank of the carbide cutters due to the altered abrasive layer properties. As described in chapter 2, for the evaluation of the deep groove grinding, especially the chipping of the cutting edge is used to describe the process quality [10]. Figure 10 shows the results in the form of the arithmetic mean roughness Ra.…”

Section: Analysis Of the Cutting Edge Qualitymentioning

confidence: 99%

Operational behaviour of graded diamond grinding wheels for end mill cutter machining

2022

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The varying related material removal rate during deep grinding of cemented carbide end mill cutters results in an unevenly wear of the grinding wheel. This study therefore presents a simulation-based model for the load-adjusted design of grinding wheels to achieve balanced radial wear, as well as an evaluation of this model. The related material removal rate along the width of the grinding wheel is determined by a Dexel based material removal simulation for different end mill geometries. Based on these results an equation is derived to adapt the abrasive layer properties to the local load differences. Three grinding wheels with different types of gradients are then manufactured by a grinding tool manufacturer based on this equation. These and two grinding wheels with constant abrasive layer properties are used for deep grinding of ten end mills each. Afterwards the radial wear of each grinding wheel is measured by a confocal microscope. An analysis of the cutting edge chipping is done to evaluate the influence on the graded grinding wheels on the cutting edge quality. It was found that a reduction of the wear difference over the grinding wheel width of 52% and an improved cutting edge quality can be achieved by using graded grinding tools. This allows the time intervals between dressing steps to be increased without compromising the accuracy of the grinding process, thus also increasing its productivity. Finally, this article shows that the presented model allows for a more balanced wear behaviour, but has to be extended by considering further factors influencing radial wear.

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“…Ceramic cutting tools bring advantages such as high wear resistance and lower surface roughness on the machined part compared to cemented carbide tools [ 1 ]. This leads to a longer lifetime of the tools as well to a higher quality of the machined part.…”

Section: Introductionmentioning

confidence: 99%

Laser Ablation Study of Cutting Ceramics with Consideration of the Beam Inclination Angle

et al. 2023

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Silicon alumina nitride (SiAlON) and alumina toughened zirconia (ATZ) ceramics are applied for ceramic cutting tools to machine, e.g., cast iron, nickel base alloys and other difficult-to-machine materials. The state of the art technology for manufacturing of the cutting tool geometry is grinding. Laser processing of ceramics is already studied in terms of ablation rate and roughness evaluation with the application of dental implant manufacturing. In the present study, laser machining of the mentioned ceramics is explored with a laser beam source of 1064 nm wavelength and 10 ps pulse duration (FWHM). The angle dependent energy specific removal rate is described in a model and the optimal pulse fluence for the different materials and the irradiation angles can be derived. For processing at irradiation angle of up to 75° no decrease of the relative absorption could be observed. For ATZ, lowest surface roughness is determined for both, orthogonal and quasi-tangential processing angle. For SiAlON, the roughness decreases constantly for higher tilt angles. A significant difference in the material answer with change of the sample composition can be detected and the results show the potential of further developing SiAlON ceramics towards machineability for laser ablation.

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A comparative analysis of ceramic and cemented carbide end mills

Cited by 17 publications

References 12 publications

Operational Behavior of Graded Diamond Grinding Wheels For End Mill Cutter Machining

Operational Behavior of Graded Diamond Grinding Wheels For End Mill Cutter Machining

Operational behaviour of graded diamond grinding wheels for end mill cutter machining

Laser Ablation Study of Cutting Ceramics with Consideration of the Beam Inclination Angle

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