A composite tool for ball endmilling

Abstract

The paper reports on the performance of a novel composite ball nose endmill that utilizes cermet and tungsten carbide indexable inserts on the same cutter body, with a view to optimizing both tool life and workpiece surface roughness. The technique exploits the asymmetric design of the cutter to position the cermet and tungsten carbide inserts appropriately, so that their characteristic tribological attributes are consistent with the functions of surface generation and wear resistance. Experimental work on ball endmilling of hardened AISI H13 tool steel is presented to illustrate the concept. The mechanism of performance enhancement of the composite tool is also detailed with reference to the flank wear pattern of the inserts and the morphology of the machined surface.

Tool life and tool wear during high-speed rough milling using alternative cutter path strategies

“…Elbestawi et al [5] found that, during the milling of hardened AISI H13 steel on ball nose end mills, tool life decreased when the axial depth of cut was increased owing to the increase in cutting speed causing higher thermal loads and thermal shocks. Koshy et al [8] reported tests involving the use of composite ball nose end mills that used cermet and tungsten carbide inserts on the same cutter when end milling hardened steel, and Yamada et al [16] investigated the e ect of coatings on tool life during the dry HSM of hardened SKD 61 steel.…”