Analysis of the surface formation mechanisms for grinding of end mill cutting tools made from cemented carbides

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The tool industry had a considerable increase in sales during the last 10 years. Especially the technology for manufacturing end mill cutting tools made from cemented carbides is common for many decades. A decisive factor for the technological success of end mill cutting tools is the wear behavior, which is influenced significantly by the manufacturing process. Thus, there is still a substantial need for the research in manufacturing end mill cutting tools made from cemented carbides with respect to the surface formation mechanisms while grinding. Flute grinding plays an essential role during tool grinding because in comparison it possesses a high material removal that goes along with a high process main time and influences the machining behavior of the milling tool notably. Different surface formation mechanisms in the contact area between the tool and the workpiece occur due to the complex contact conditions, which has a significant influence on the surface quality, the peripheral-zone properties and the tool strength. Within the first research period predominant ductile surface formation mechanisms were observed, whereas the generated surfaces varied significantly between the bottom of the flute and the rake face. The generation of knowledge about the relationship between the grinding wheel specification and the process parameters with the process behaviour and surface quality in the flute was used to develop a process model for flute grinding. Concerning the results it can be assumed that an adaption of the grinding tool to the varying contact conditions between grinding wheel and workpiece during flute grinding within the active grinding wheel width is reasonable in order to optimize flute grinding processes. Hence, within the second research period it will be clarified how the findings of the first research period can be transferred to the use of load-adapted, graded grinding wheels and furthermore the interaction with the milling process will be analyzed.