Design and fabrication of double-circular-arc torus milling cutter

Focusing on the feed rate limitation and high cutting force of regular torus milling cutter in machining dies, a double-circular-arc torus milling cutter is designed and fabricated in this work. The geometric characteristics, cutting force, and milling process of the milling cutter are analyzed and presented. The mathematical models of the cutting edge and radius of the main-circular-arc cutting edge are built. To ensure the cutting performance of the milling cutter, a grinding method combining theory, simulation, fabrication, and test is proposed for the fabrication of the milling cutter. The grinding model is built through coordinate transformation. The evaluation of grinding accuracy is proposed. The milling cutter is shaped on a five-axis NC grinding machine, and its accuracy is tested by a tool test center. The test results show the feasibility of the grinding process and the grinding accuracy is ensured. To verify the cutting performance of the proposed double-circular-arc torus milling cutter, milling experiments are conducted. The cutting force and surface roughness of ball-end milling cutter, regular torus milling cutter, and two double-circular-arc torus milling cutters are measured and compared. It is shown that the double-circular-arc torus milling cutters can generate low cutting force and low surface roughness.