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

在本项目中，将研究一种新的铣刀，其主要特点是不同形状的切削槽，使其适合于粗加工和精加工。直径排列的切削刃具有相同的微观几何形状。两个凹槽有锋利的刃口，而另外两个凹槽的侧面有一个倒角。同时，带有锯齿刃的凹槽在径向向内略微凹陷。这种设计使倒角的刃口可以提高加工稳定性，而锋利的刃口由于径向突出而形成最终表面，从而获得高表面质量。与粗立铣刀相比，可获得更好的表面质量；与精立铣刀相比，可获得更高的生产率。本项目的主要目标是对同时涉及的粗加工和精加工刃口在生产率和可实现的加工表面质量方面的相互作用有一个基本的了解。主要指标是可实现的稳定性和表面质量。为了实现主要目标，这些刀具的制造考虑了制造公差和再现性，然后通过实验和计算检验了由此产生的切削力、工艺稳定性和表面质量。最后，基于所获得的知识，将开发工具的过程优化设计。

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.