Abstract
The ability of serrated end mills to reduce cutting forces and improve chatter-free machinability is governed by their serration profiles. This paper presents a comparative analysis of the cutting behavior of two differently profiled serrated end mills, of which one has a standard trapezoidal profile, and another has a non-standard inclined-circular profile. Established force and stability models are used to predict the cutting behavior that is experimentally validated. For cutting aluminium,cutting forces for the non-standard inclined-circular cutter are lower than the standard trapezoidal cutter. However, from the chatter-free stability point of view, both cutters perform similarly.
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