Machining, Measurement, and Control Laboratory

2 0 0 0    J o u r n a l    P a p e r

A Study on Endmilling of Hardened Steel (1st Report)
-- Simplified Prediction Model for Cutting Forces and Control for Constant Cutting Forces Using this Model --
Yoshiaki KAKINO, Hirotoshi OHTSUKA, Heisaburo NAKAGAWA, Toshiki HIROGAKI and Masashi SASAKI

This paper deals with the mathematical model for cutting forces by (Al,Ti)N-coated micro-grain carbide radius endmill cutter during endmilling of hardened steel used for dies and molds. A quadratic polynomial model was proposed for cutting forces based on response surface methodology by two variables of the engagement angle of cutting tool and the maximum undeformed chip thickness. In endmilling of hardened steel, the control of cutting forces is especially important because chipping occurs soon if severe cutting forces are present at the cutting edge. The control of cutting forces in profile endmilling which includes both straight and corner cutting, was very effective using this model. Furthermore, response surface form was applied for the case of worn endmill that had a cutting edge with large negative rake angle, and it was found that the control of cutting forces was also possible with some compensation even for the worn tool.

Key words: endmilling, hardened steel for dies, (Al,Ti)N-coated carbide tool, tool wear, rake angle, mathematical model, cutting force, response surface methodology

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