Abstract
Ultra-small diameter cemented carbide ball end mills have been developed. Tools having a radius of ball nose of 10μm have been manufactured by electrical discharge machining (EDM), because conventional methods cannot be readily applied to microtool fabrication. The spherical shape of the tool cutting part is realized via an electrode wear phenomenon in EDM. Milling of brass using fabricated tools has been performed at 2 μm axial depth of cut and 4 μm pick feed. Although simulation suggests the surface roughness (Rz) in tool feed direction to be 0.05 μm at 100 μm/s feed speed, in actual milling, the surface roughness is 0.42 μm, due to plastic deformation of the workpiece. Investigations indicate that the tool life decreases rapidly when the feed speed or the body length increases above a certain value. The tool life can be improved, especially at low feed speeds, by changing the angle between the two planes that each contain one ball end cutting edge from 180°to 90°.
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