Study on wavy-edge plunge milling cutter with chip split and cutting load reduction function

Abstract

The plunge milling feeds along the cutter axis, and the cutting load is concentrated in the cutter axis with greater rigidity, which is a rough machining process that allows greater machining processing parameters. At present, due to the cutting performance of plunge milling cutter, its efficiency advantage is difficult to give full play, and the application scope is very limited. For this reason, this paper introduces the chip split principle of wavy edge into plunge milling, and develop a high-performance plunge milling cutter that can reduce the cutting force and cutting vibration. The mechanism for wavy edge to reduce load is revealed from the perspective of the geometric characteristics of cutting layer, and the cutter structure of radial dislocation matching axial dislocation is proposed. The critical condition for effective chip split is derived, which provides a theoretical basis for cutter design and machining parameter selection. Considering the rough machining characteristics, the model designing, material selection and manufacturing process for the insert blade, cutter head and cutter body of the wavy-edged plunge milling cutter are proposed, and the reasonable value range of its key cutter geometric parameters are clarified. The arranged plunge milling experiment of 40Cr stainless steel shows that the vibration amplitude of wavy edged cutter is reduced by more than 90 % compared with straight edge cutter, and the machining stability is higher. At the same time, the cutting force is reduced by about 50 %, allowing larger feed per tooth.