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IJAT Vol.13 No.1 pp. 101-108
doi: 10.20965/ijat.2019.p0101
(2019)

Paper:

Surface Profile Analysis in Milling with Structured Tool

Fumihiro Uchiyama*,†, Akihiko Tsuboi**, and Takashi Matsumura***

*Uchiyama Hamono Co., Ltd.
3-8-1 Ryoke, Naka-ku, Hamamatsu, Shizuoka 430-0852, Japan

Corresponding author

**The Graduate School for the Creation of New Photonics Industries, Hamamatsu, Japan

***Tokyo Denki University, Tokyo, Japan

Received:
July 1, 2018
Accepted:
September 18, 2018
Published:
January 5, 2019
Keywords:
surface finish, milling, structured tool, cutter axis inclination, simulation
Abstract

Novel end mills with micro-scale structures have recently been developed to promote cutting performances with cutting forces, chip controls, and tool wears. However, the surface profiles are formed corresponding to the structures on the tool edges. The surface finishes, therefore, are worse than those of cuttings with straight edges of the end mills. This paper discusses surface profiles in milling with the structured tool and the cutter axis inclination. An analytical model is presented to simulate the surface profiles for the tool edge shape, the cutting parameters and the cutter axis inclination. Because the surface profiles are controlled in the simulation, the optimum cutting parameters are determined to reduce the surface roughness. Micro-scale nicks were fabricated on polycrystalline diamond edges with a laser machine tool. The sizes and pitches of the nicks were controlled by the laser processing parameters. The cutting tests were conducted to measure the surface profiles. The presented surface profile model was validated by comparing the simulated and the measured surface roughnesses. The surface finish can be improved in milling with the cutter axis inclination in the optimum cutting parameters.

Cite this article as:
F. Uchiyama, A. Tsuboi, and T. Matsumura, “Surface Profile Analysis in Milling with Structured Tool,” Int. J. Automation Technol., Vol.13, No.1, pp. 101-108, 2019.
Data files:
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Last updated on Aug. 21, 2019