Operation Safety and Performance of Milling Cutters with Shank Style Holders of Tool Inserts

Abstract

Abstract Paper introduces results related to the application of advanced milling cutters provided with shank style of tool insert holder. Design of prototypes of tool bodies is based on calculations of theoretical number of tool edges. Bodies of milling cutter include holes to mount tool insert holder while two types of insert shape as round and octagonal are used in milling cutter design. Based on measuring of cutting forces when milling planar surfaces, critical cutting conditions leading to the tool damage are identified and they are compared with commercial milling cutters. Applying cutting force data, operation safety is being studied concerning outer appearance of tool failure. Application of Finite Element Method is used to assess the critical spots leading to the insert holder failure. Maximum stress which brings about ductile fracture of shank style's insert holder has been found out by FEM modelling. Operation capability of tool inserts is compared with tool performance data. Surface roughness and short term tool wear testing was used as tool performance criteria to asses capability of new cutting tools in face milling operations. Surface quality produced by that kind of milling cutter is referred to as semi finishing and finishing cut. Advantages and limitations of that milling cutter innovation are discussed. Selection and/or peer-review under responsibility of the Branch Office of Slovak Metallurgical Society at Faculty of Metallurgy and Faculty of Mechanical Engineering, Technical University of Kosice.