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The influence of end mill helix angle on high performance milling process

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Abstract

The results of experimental research on the influence of the helix angle on high performance milling of AlZn5.5MgCu alloy are presented. End mills with a wavy shape of a cutting edge, dedicated to rough high performance machining, were used. The helix angle was changed in the range of 20° to 50° with a step of 5°. During the milling tests, three cutting force components were measured. After each test cutting, chips were collected and analyzed. A recording of the chip evacuation process using a high-speed camera was also conducted. The influence of the helix angle on cutting force components was determined and the mathematical models of the forces were calculated. The significance of coefficients in the obtained equations was analyzed as well. The recorded images of the chip evacuation were analyzed. The displacement and the angle of the chip evacuation were determined. Based on the analysis of the selected images the impact of the helix angle on the direction and evacuation velocity of chips was determined. The size and shape of the obtained chips was also analyzed.

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Abbreviations

a p :

Axial depth of cut

a e :

Radial depth of cut

D c :

Cutting tool diameter

n :

Rotational speed of cutting tool

v f :

Feed speed

v c :

Cutting speed

v ch :

Evacuation velocity of the chip

f z :

Feed per tooth

f p :

Sampling rate

λ :

Helix angle

ώ :

Level of significance

δ ch :

Evacuation angle of the chip

F f :

Feed cutting force component

F fN :

Normal to feed cutting force component

F a :

Axial cutting force component

Q v :

Cutting volume

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Authors and Affiliations

  1. Department of Manufacturing Techniques and Automation, The Faculty of Mechanical Engineering and Aeronautics, Rzeszow University of Technology, ul. W. Pola 2, 35-959, Rzeszow, Poland

    Marcin Plodzien, Jan Burek, Lukasz Zylka & Pawel Sulkowicz

Authors
  1. Marcin Plodzien
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  2. Jan Burek
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  3. Lukasz Zylka
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  4. Pawel Sulkowicz
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Corresponding author

Correspondence to Lukasz Zylka.

Additional information

Recommended by Editor Hyung Wook Park

Marcin Plodzien completed his Ph.D. in Mechanical Engineering in the analysis of the high efficient milling process of aluminum alloys. He is currently an Assistant Professor in the Department of Manufacturing Techniques and Automation at Rzeszow University of Technology. His research interests include milling processes, cutting of aerospace materials, chip formation process, cryogenic cooling of cutting and numerical analysis of cutting tool construction.

Jan Burek is a Professor and the Head of the Department of Manufacturing Techniques and Automation at the Faculty of Mechanical Engineering and Aeronautics in the Rzeszow University of Technology. His main research interests include high speed and high performance machining as well as modern tool manufacturing methods. His interests pertain to machining optimization, modeling and monitoring of the cutting processes.

Lukasz Zylka completed his Ph.D. in Mechanical Engineering on diagnostics of the gear grinding process and is currently an Assistant Professor in the Department of Manufacturing Techniques and Automation at Rzeszow University of Technology, Poland. His research interests include creep feed grinding, grinding of aerospace materials, high-pressure cooling in grinding processes, active grinding wheel cleaning process and also cooling nozzle construction.

Pawel Sulkowicz received his M. Sc. in 2014 from Rzeszow University of Technology. He is an assistant researcher and Ph.D. candidate at the Rzeszow University of Technology. His main research interests include high perform-ance machining and optimization of machining processes.

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Plodzien, M., Burek, J., Zylka, L. et al. The influence of end mill helix angle on high performance milling process. J Mech Sci Technol 34, 817–827 (2020). https://doi.org/10.1007/s12206-020-0131-6

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  • DOI: https://doi.org/10.1007/s12206-020-0131-6

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