Analysis of the influence of the location schemes of form-forming cutting elements on the deformation processes of step face milling cutters

Abstract

In recent times, methods of finishing flat surfaces with face mills equipped super-hard materials have become widespread. However, the non-stationarity of the cutting process, which is characteristic of face milling processes, leads to variable deformations of the technological system, which can negatively affect the initial quality indicators of the responsible surfaces, the necessary characteristics of contact stiffness, wear resistance, reliability of mechanisms and machines depend on their processing. The paper investigates the axial displacements of the forming cutting elements as a result of the elastic deformation of the body 360 mm diameter face mill step cutter, which is equipped with super-hard tool material (hexanite-R). The effect of geometrical parameters was studied, change in the radial arrangement of the finishing cutting element, a change in the diameter of the wedge hole on axial movements during the finish milling of gray cast iron. It was established that reducing the distance of the radial arrangement of the finishing cutting element allows to significantly reduce the axial movements of the forming cutting elements, but will limit the milling width. The influence of the separation of the finished cutting element from the rough ones on the axial displacements was studied. Axial displacements of three types of cutters are compared: a step face mill; a step face mill with separation of the finishing cutting element; a step face mill with a change in the radial location of the finishing cutting element. The results of the research confirm that there is a reserve for improving the quality of processing, by analysing the geometric parameters of face mill and developing new designs that will ensure the required quality of processing.

Keywords

• step face mills
• oblique cutting
• face mill
• face milling