Prediction of Process Forces and Stability of End Mills with Complex Geometries

In order to optimize the cutting performance of end mills, the geometry of such cutters is optimized by toolmakers constantly. As a result of geometric changes, process forces can be reduced, i.e. by serrated end mills. Tools with unequal helix angles can lead to an increase of process stability. In this paper, a method to calculate the process forces of end mills with complex geometries is presented. The method for calculating the process forces is designed for the application for stability analysis of end mill cutters with complex geometries. A basic introduction of the method for the stability prediction of such tools is given. Cutting forces of end mills are analyzed at incremental axial depth of cuts to show the influence of the tool geometry on the process forces. The comparison with experimental data verifies this method and shows the influence of further effects on the process forces. Furthermore, stability charts obtained with the Semi-Discretization Method are presented to show the potential of end mills with complex geometries regarding stability improvement. (C) 2014 Elsevier B.V.