High-Speed Micromilling of Composite and Aluminum Alloy Parts

Abstract

The paper deals with the design of the cutting part of complex-profile cutters with high productivity and surface quality. Numerical experiments carried out using the finite element method made it possible to determine the stresses and strains in the layer of the cut material when machining with multifaceted milling cutters of a new type and indirectly estimate the specific cutting forces. The required dimensions and shape of the cutting wedge are set with account for various geometric parameters of the cutting part, properties of the workpiece material, and cutting conditions. This made it possible to obtain a three-dimensional model of an end mill with a trapezoidal tooth and 700 cutting edges. Experimental studies also showed a change in the morphology of chips with a size of about 2 microns, which is in good agreement with the results of preliminary estimates by the finite element method. The productivity of processing with milling cutters of a new design can be improved by increasing the number of single cutting cycles up to4000–6000 s–1.