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IJAT Vol.14 No.1 pp. 26-37
doi: 10.20965/ijat.2020.p0026
(2020)

Paper:

Experimental Investigations on Cutting Phenomena in Shoulder Cutting of Hardened Die Steel with Small Diameter End Mill: Effects of Left Hand Helical Tool

Takumi Imada*1, Keiji Ogawa*2,†, Haruki Kino*3, Heisaburo Nakagawa*4, and Hitomi Kojima*5

*1Industrial Research Center of Shiga Prefecture
232 Kamitoyama, Ritto-shi, Shiga 520-3004, Japan

*2Ryukoku University, Otsu, Japan

Corresponding author

*3Mitsubishi Hitachi Tool Engineering, Ltd., Tokyo, Japan

*4Nakagawa Machining R&D Center, Wakayama, Japan

*5Big Daishowa Seiki Co., Ltd., Higashiosaka, Japan

Received:
July 4, 2019
Accepted:
October 12, 2019
Published:
January 5, 2020
Keywords:
micro-end-milling, left hand helical tool, cutting force, tool wear, machining accuracy
Abstract

This study deals with shoulder cutting phenomena in micro-end-milling of hardened die steel. Demand for micro-end-milling for products in the medical, optical, and electronics industry is increasing. However, in machining with a small diameter end mill that has diameter of e.g., 0.5 mm, the rigidity of the tool itself is low; therefore, cutting conditions must be set to low values to achieve stable machining. We revealed that cutting phenomena became unstable because the end cutting edge was damaged early in shoulder cutting. Therefore, we experimentally prepared a left hand helical tool with a right hand cut to perform complete processing by improving the strength of the end cutting edge. Cutting experiments were carried out while measuring cutting force and observing cutting phenomena, end cutting edge, and machined surface via scanning electron microscopy (SEM). We determined the effects of such tools on fundamental phenomena in shoulder cutting with a small diameter end mill. The rake angle of the tool was improved based on experimental analysis of the damage mechanism of the cutting edge in the shoulder cutting. A result of the examination to investigate the influence of the difference in rake angle on chip evacuation showed that the chip discharge direction was affected by the rake angle; when the angle is blunt, the chips were discharged upward, and the chip discharge performance improved.

Cite this article as:
T. Imada, K. Ogawa, H. Kino, H. Nakagawa, and H. Kojima, “Experimental Investigations on Cutting Phenomena in Shoulder Cutting of Hardened Die Steel with Small Diameter End Mill: Effects of Left Hand Helical Tool,” Int. J. Automation Technol., Vol.14, No.1, pp. 26-37, 2020.
Data files:
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Last updated on Feb. 17, 2020