Model-based phase shift optimization of serrated end mills: Minimizing forces and surface location error

Abstract

Serrated cutting tools emerged for higher chip removal in rough milling operations. In this paper, attention is simultaneously paid to cutting forces and surface quality. The mechanics of the milling system with serrated end-mills was studied using force and surface topography models. A stationary milling force model was developed including the main geometric parameters of the serrated profile. For a complete understanding, a surface topography model was developed to predict the resulting machined surfaces. To ensure reliability and generality, the characterizations of three different tools and respective experimental validations were done. Then, the effect of the phase shift parameter ψ among cutters was set on the target. A search algorithm, combining the results from both models, was proposed to find the best tools that minimize simultaneously forces and roughness. These results are useful for toolmakers in tool design step, as for machinists and process engineers, when it comes choosing the optimum tool parameters.