Parameter optimization of a micro-textured ball-end milling cutter with blunt round edge

Abstract

Titanium alloys is a typical difficult-to-cut material with many machining problems, build-up-edge, large cutting force, and high cutting heat. Previous research has shown that micro-texture on the tool surface can solve the above problems potentially, and that a blunt round edge of the cutting tool can enhance its strength and improve the tool wear resistance. Therefore, towards an optimal parameter of micro-texture and blunt round radius, a finite element method (FEM) simulation and an experiment are carried out, where the test result provides a set of data for a genetic algorithm–based prediction model. The optimized parameter combinations of the micro-textured ball-end milling cutter with a blunt round edge are obtained and compared in a set of experiments. The optimized parameters refer to a 40-μm radius of the blunt round edge, a 40-μm micro-texture diameter, a 175-μm spacing, a 120-μm distance from the cutting edge, and an 80-μm depth.