Design of a Roughing-Finishing-Tool

• Applicant: Professor Dr.-Ing. Berend Denkena
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 533921562

Due to different requirements, milling processes are divided into roughing and finishing processes. The goal of roughing processes is to achieve high productivity. This can be achieved by a flank face chamfer, which suppresses vibrations occurring in the process at high depths of cut. However, the contact between the chamfer and the final surface leads to a reduced surface quality. For finishing processes, therefore, unchamfered tools are used to generate the final surface. As a result, tool changes and long finishing times significantly increase process times. The use of a single tool could therefore significantly reduce process times during milling. This can be achieved by having one tool with both, chamfered and unchamfered cutting edges. In addition, the chamfered cutting edges are radially recessed so that they do not get in contact with the final surface. The final surface is therefore only generated by the unchamfered cutting edges. In the completed DFG project 281989189, a significant increase in process stability compared to conventional finishing tools and at the same time, the guarantee of a high surface quality could be demonstrated. So far, however, there are no approaches for the geometrical design of the roughing-finishing tool concept. It must be taken into account, for example, that a larger chamfer width allows an increased productivity, but at the same time is associated with greater wear. In addition, due to the small size of the radial offset, manufacturing accuracy is of crucial importance. If the radial offset is chosen too small, the chamfer may get in contact with the final surface due to manufacturing deviations. On the other hand, a too large radial offset has a negative effect on productivity. Besides the chamfer geometry, the cutting edge rounding has a significant influence on wear and surface quality. The cutting edge rounding has been so far chosen based on experience. A high potential to optimized the cutting edge rounding offers the cutting tool material based design of the rounding as demonstrated in the completed DFG project. Based on this, the goal of the planned project is therefore the availability of a practical method for the geometrical design of the tool. This will be developed in this project together with the application partner Josef Neumüller Werkzeugschleiferei GmbH.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: Josef Neumüller Werkzeugschleiferei GmbH