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

在过去的10年里，工具行业的销售额有了相当大的增长。特别是用于制造由硬质合金制成的立铣刀切削刀具的技术已经普遍使用了几十年。立铣刀技术成功的一个决定性因素是磨损性能，而磨损性能受制造工艺的显著影响。因此，仍然有大量的研究需要在制造由硬质合金制成的立铣刀切削工具方面的表面形成机制，而磨削。在刀具磨削过程中，沟槽磨削起着至关重要的作用，因为相比之下，它具有高的材料去除率，沿着高的加工主时间，并且显著地影响铣刀的加工行为。由于复杂的接触条件，在刀具与工件的接触区域会产生不同的表面形成机制，从而对表面质量、周边区性能和刀具强度产生重要影响。在第一个研究期间主要的韧性表面形成机制进行了观察，而所产生的表面之间的凹槽和前刀面的底部变化显着。砂轮规格和工艺参数之间的关系的知识的产生与过程中的行为和表面质量的长笛被用来开发一个过程模型的长笛磨削。考虑到结果，可以假设，为了优化沟槽磨削过程，在有效砂轮宽度内的沟槽磨削期间，磨削工具对砂轮与工件之间的变化的接触条件的适应是合理的。因此，在第二个研究周期内，将阐明如何将第一个研究周期的发现转移到使用负载适应的分级砂轮上，并进一步分析与铣削过程的相互作用。

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.