Investigations on the Influence of Serration Parameters on Cutting Forces

Abstract

Serrated cutters, with their complex geometries, reduce cutting forces, and hence find use in the high-productivity milling of difficult-to-cut materials. Variations in serration profiles and parameters such as amplitudes, wavelengths and phase shifts influence the degree to which cutting forces can be reduced. In an effort to develop guidelines to preferentially design serrations to reduce cutting forces and improve productivity, this paper investigates the influence of serration parameters on cutting forces. A geometric force model explaining the mechanisms contributing to reducing forces is presented, and validated experimentally. Sensitivity analysis is then carried out on the validated model to understand the influence of serration parameters. It is observed that for a sinusoidal serration profile, for defined cutting conditions, the phase shift of the serrations between successive teeth contributes more to reducing forces than the serration amplitude and/or the wavelength. These results are instructive for the design of better serrated cutters.