Investigation of the effects of a novel milling tool for roughing and finishing operations.

在这个项目中，将研究一种新的铣刀，其主要特征是切削槽形状的不同设计，这使得它适合粗加工和精加工。直径排列的切削刃具有相同的微观几何形状。两个笛子有锋利的切削刃，而另外两个在侧面有一个倒角。同时，具有倒角切削刃的凹槽在径向方向上略向内凹陷。这种设计使倒角切削刃增加了加工的稳定性，而锋利的切削刃由于其在径向上的突出而产生最终表面，从而实现了高表面质量。与粗加工立铣刀相比，可以获得更好的表面质量，与精加工立铣刀相比，可以获得更高的生产率。这个项目的主要目的是获得一个基本的理解，在生产率和可实现的加工表面质量方面，同时涉及的粗加工和精加工切削刃之间的相互作用。主要目标是可达到的稳定性和表面质量。为了实现主要目标，在考虑制造公差和再现性的情况下制造这些刀具，然后通过实验和计算对产生的切削力、工艺稳定性和表面质量进行检查。最后，根据所获得的知识，对刀具进行工艺优化设计。

In this project, a new milling tool will be investigated, whose key feature is the varying design of the shape of the cutting flutes, which makes it suitable for roughing and finishing operations. The diametrically arranged cutting edges have the same micro geometry. Two flutes have sharp cutting edges, while the other two have a chamfer on the flank face. At the same time the flutes with thechamfered cutting edges are slightly recessed inwards in radial direction. This design enables the chamfered cutting edges to increase the process stability while the sharp cutting edges due to their protrusion in radial direction generate the final surface, and thus, a high surface quality is accomplished. In comparison to roughing end mills a better surface quality and in comparison tofinishing end mills a higher productivity can be achieved. The main objective of this project is to acquire a basic understanding of the interaction between simultaneously involved roughing and finishing cutting edges in terms of productivity and the achievable quality of the machined surface. The main targets are the achievable stability and surface quality. To achieve the main objective, these tools are manufactured, taking under account manufacturing tolerances and reproducibility, and then the resulting cutting forces, process stability and surface quality are examined experimentally and computationally. Finally, based on the gained knowledge, a process-optimized design of the tool will be developed.