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

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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.