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DESIGN AND DEVELOPMENT OF CUTTING TOOL FOR MILLING

Research · November 2015

DOI: 10.13140/RG.2.1.3636.8722

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 DESIGN AND DEVELOPMENT OF CUTTING TOOL FOR MILLING

F.Y.Wong

Faculty of Mechanical Engineering, Universiti Malaysia Pahang (UMP), 26600 Pekan, Pahang,
Malaysia, Phone: +60179064724
Email: yong6207@gmail.com

ABSTRACT

The design and development of cutting tool for milling requires a number of consideration such
as thermal distribution, cutting force and torque applied to the tool, wear, vibration and more.
This study is to design and develop a cutting tools for milling process. The cutting tool specifically
end mill tool is designed by using SolidWorks 2012 and the static analysis was performed. The
external loadings applied are 26 N/m of torque is applied to the end mill cutter surface and 1250
N of forces is applied to one of the tool surface. From the simulation by using SolidWorks 2012,
the minimum FOS is 12 and the maximum resultant displacement is 0.0969mm. From the result
obtained, the tool is less likely to break.

Keywords: Graphite; electrode wear rate; positive polarity; EDM.

INTRODUCTION

In milling process, the chip separation process occurs at the edge of the shear zone with lateral
plastic flow of material which form burr [1]. The performance of a cutting tool affected by three
factors that play the important role: hardness, wear resistance, chemical inertness and fracture
toughness of the workpiece material [2]. Notching at the tool nose and depth of cutting region
was a prominent failure mode when machining nickel-based alloys due to the combination of high
temperature, high workpiece strength, work hardening and abrasive chips [1]. Special physical
condition such as the stress and high temperature gradient most likely to cause tool wear [1]. Tool
life is important to save time from replacing the tool and reset the tool during machining [3].
Carbide tips type cutting tool usually suffer flank wear as shown in Figure 1 from Noor and
Kadirgama [3]. AISI P20 is milled by using carbide coated insert in the research and it is a high
speed steel to machine mould and has the tensile strength of 1044 MPa at room temperature and
a hardness ranging from 280 to 320 HB [3-5]. Tool life decreases with the increases of cutting
speed, federate, axial depth and radial depth of cut [4]. The chemical composition of the tool also
affect the wear rate of the carbide coated tool [1].

Flank wear

Figure 1. Flank wear (Noor and Kadirgama, 2009)

 When design a cutting tool for milling purposes, there are three main parameters to
consider namely temperature distribution during the machining, torque produced and the cutting
force exerted on the tool. This is important in order to prevent tool failure. The temperature during
the machining can rises up to 1000oC in the cutting zone at the tool-chip interface [6]. In the end
milling of AISI 618 stainless steel workpiece material using carbide inserts PVD coated with a
layer of TiN, the torque measured is as tabulated in Table 1 [7, 8]. From the result, the maximum
torque is 23Nm thus the tools to be designed need to be able to withstand torque of more than
23Nm to prevent tool failure. From the experiment result by Kadirgama, et al. [9] by using
Hastelloy C-22HS as workpiece material, the cutting force is as shown in Table 2 and from the
result, the cutting tools to be designed need to be able to withstand forces of more than 1250N to
prevent tool failure. From the experiment by Fuh and Hwang [10], the maximum milling force
recorded by using 20mm and 30o helix angle of milling tools is 722.7N. According to Dombovari
and Stepan [11], the forces acting on the tool in orthogonal cutting method can be illustrated as
shown in Figure 2 where by the shear force, Fs and normal force, Fn is as expressed below:

𝐹𝑠 = 𝑓𝑡 cos ∅ − 𝑓𝑟 sin ∅ (1)

𝐹𝑛 = 𝑓𝑡 sin ∅ + 𝑓𝑟 cos ∅ (2)

Table 1. Experimental torque measured (Kadirgama, et al, 2009)

Cutting speed, Feed rate, Axial depth, Radial depth, Torque,

m/min mm/rev mm mm Nm
140 0.15 1.0 2.0 10
140 0.20 1.0 3.5 13
100 0.15 1.0 3.5 16
180 0.15 1.0 3.5 13
140 0.10 1.0 3.5 8
140 0.15 1.0 5.0 16
100 0.15 1.5 2.0 16
140 0.10 1.5 2.0 7
100 0.20 1.5 3.5 14
140 0.15 1.5 3.5 14
180 0.20 1.5 3.5 18
180 0.15 1.5 2.0 12
140 0.20 1.5 2.0 13
140 0.20 1.5 5.0 18
140 0.15 1.5 3.5 13
180 0.10 1.5 3.5 8
100 0.10 1.5 3.5 14
100 0.15 1.5 5.0 22
140 0.10 1.5 5.0 14
180 0.15 1.5 5.0 15
140 0.15 1.5 3.5 18
140 0.15 2.0 5.0 20
140 0.20 2.0 3.5 23
140 0.10 2.0 3.5 13
140 0.15 2.0 2.0 11
100 0.15 2.0 3.5 23
180 0.15 2.0 3.5 16

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 Table 2. Experimental cutting force (Kadirgama, et al, 2008)

Cutting speed, m/min Feed rate, mm/rev Axial depth, mm Exp. Force, N
140 0.10 2.0 684.00
140 0.20 1.0 687.00
100 0.15 1.0 458.95
100 0.15 2.0 1050.00
140 0.15 1.5 685.00
100 0.10 1.5 449.51
180 0.10 1.5 310.54
180 0.15 2.0 876.00
180 0.20 1.5 880.00
140 0.20 2.0 1250.00
180 0.15 1.0 300.21
140 0.15 1.5 682.00
140 0.10 1.0 100.54
100 0.20 1.5 1010.00
140 0.15 1.5 690.00

The knowledge of force involve is important to design a tool that able to withstand the
repective forces as knowing the resultant forces alone is not adequate to simulate the tool during
the design stage. Solid and coated carbide also has better hardness for higher cutting speed and
material removal rate compared to High-speed tool steel (HSS) [12]. The rake angle of the tool
also affect the contact region and friction between chip and tool [13]. The side burr thickness
decreased linearly,as the radial rake angle increased and almost constant when the radial rake
angle ranging from -30 to 30 deg [14].

Figure 2. Forces acting on a tool in 2D cutting (Dombovari and Stepan, 2015)

For high speed cutting, the choice of tool materials highly dependent on the wear
processes between the workpiece and cutting edge [15]. Coating carbide tools initially developed
by using Chemical Vapour Deposition (CVD) technique and most of the multi-layer coating
materials contain a combination of TiN, TiC, Ti(C,N) and Al2O3 with different deposition
sequences to improve tool life [16]. TiC coatings enable high resistance to flank wear, TiN
coatings allow little crater wear, A12O3 or ALON remain chemically stable even at high
temperatures because of their low avidity, and multiple coatings with ALON show less crater
wear [15]. Oxide-coated tools has better performance when use for dry cutting operation [17].
Fracture and chipping occurred approximately 50% of the tool damage cases and it started from
the thermal cracks generated in the straight cutting edge [18]. Cryogenic treatment is an extreme
cold treating process range -125 to -196oC to improve properties of high precision parts and
components such as machining tools as it increases the hardness and improves the hardness
homogeneity [19, 20]. Cryogenic treatment of tools able to guarantees their quality after
regrinding or resharpening unlike coating [21]. Deep cryogenically treated samples of H13
improved the wear properties of the H13 tool steel by forming a uniform and very fine carbide
particles [20].

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 The purpose of this project is to design and develop a cutting tools for milling process.
Thus, the important parameters such as the temperature distribution, cutting force and torque acted
on the tool during machining were studied to help in the designing stage and simulation of the
design.

METHODOLOGY

The fatigue analysis on the cutting tool can be performed through an integrated Finite Element
(FE) based analysis providing appropriate tool material by using Marrow correction [22-24].
Finite element method able to predict the deformation, stresses and strain in the workpiece as well
as the load on the tool under the specified cutting parameter [25]. Thirdwave AdvantEdge is used
to model the cutting process of HASTELLOY C-22HS workpiece where the element distortion
is updated by refining large element, remeshing distorted elements and corsening small elements
[25]. Finite Element Method (FEM)-based techniques can provide more detailed information not
only for cutting forces but also for tool stresses and temperatures [26]. Static cutting force increase
with axial depths of cut when using a new cutter [27]. The attempt used in this project design and
development is to use cryogenic treated H13 tool steel as the material for the end mill as it able
to provide a uniform material hardness distribution compared to coated tool which desirable for
resharpening and regrinding of tool [21]. The modelling of the end mill is designed as detail as
possible as simulation end mill geometry by using simple beam models are inaccurate [28]. The
designed H13 tool steel end mill is as shown in Figure 3.

Figure 3. 3D modelling of a 25mm diameter and 180mm long end mill generated by using
PhotoView 360

Static Analysis

Static analysis was performed on the designed end mill to determine the possibility of the tool to
break or fail under static loading. The finite element analysis was done by using SolidWorks 2012
Simulation by considering the maximum force and torque exerted on the tool during the cutting
process according to the literature studied. The external loadings applied are 26 N/m of torque
and 1250 N of forces to one of the tool surface. The physical properties of H13 tool steel used is
7800 kg/m3 density, 1990 Mpa tensile strength, 1650 Mpa yield strength, 0.3 poissons ratio and
81.0 Gpa shear modules. Figure 4 shows the location where the force and torque been applied on
the end mill tool to run the simulation. The green coloured arrows indicates the fixture region

4
where the tool is hold in fixed position visualizing the tool holder holding effect to obtain a more
realistic result.

1250N external
forces

(a)

26 Nm external
torque

(b)

Figure 4: FEM external load setup (a) force and (b) torque

RESULTS AND DISCUSSION

From the simulation by using SolidWorks 2012 Simulation, the result obtained is as shown in
Figure 5 below consist of the FOS and resultant displacement in millimeter (mm). Figure 5 (a)
shows that the critical region of the design is at the end of the tool holder which has the minimum
FOS. It also shows that the particular region is where the stress concentration occurs and extra
caution need to be taken in designing and selecting the tool materials. The FOS color tone also
shows that the stresses is more in the region where there are changes in geometry of the tool
design. On the other hand, Figure 5 (b) shows that the maximum resultant displacement occurs at
the tip of the cutting tool edges. From the simulation by using SolidWorks 2012, the minimum
FOS is 12 and the maximum resultant displacement is 0.0969mm as shown in Figure 5. From the
result obtained, the tool is less likely to break.

5
 (a)

(b)

Figure 5. Solidworks 2012 simulation result (a) FOS and (b) resultant displacement

However, in actual practice, it is subjected to dynamic loading, vibration and thermal

stress which can causes tool failure. Even a slight vibration may cause the premature failure of
the tool [29]. Even the high temperature in tools could cause it to wear rapidly and constraint the
tool life [30]. Temperature distribution is important to determine the suitable material for the tool
and limit the tool application.

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 CONCLUSIONS

In this study, it was attempted to develop a cutting tool for milling purposes. From the literature
study, it was decided to use cryogenic treated H13 tool steel as the material for the end mill as it
able to provide a uniform material hardness distribution compared to coated tool. From the
simulation, it shows a good result with FOS of 12 and resultant displacement of 0.0969 mm.
However, the simulation by using a more specific software such as Thirdwave AdvantEdge is
recommended for better result in term of thermal stresses, tool performances and vibration. In
conclusion, the objective of this study is achieved.

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