CAE Analysis of Single-Edge Micro End Mills - Methodology and Results

Abstract

The design of micro end mills requires to take various partly conflicting aspects into account, which prohibit downsizing of conventional end mills. To support the design and manufacture of micro end mills a guidance criterion was established by renowned researchers of the field. Within the work presented here the guidance criterion was the basis for a detailed CAE/FEM analysis to deepen the understanding of micro end mill design. The main topic was to determine the influence of the helix angle on the maximum principal stress (?1) at critical regions of the tools. In addition to that a study with regard on total tool length and the influence of the rounded edge areas was done. Both of the investigated aspects showed a considerable impact on the tools? failure behaviour, displacement of the cutting edge corner and stiffness.