切りくず流出の解析に基づく高性能エンドミルの開発

抄録

To realize a high-efficiency machining by solid square end mill, it is important to increase the number of teeth, improve the rigidity by increasing the moment of inertia of the cross-sectional area, and also to design a flute geometry that can evacuate the generated chips smoothly. However, it is not easy to satisfy all the above specifications, as a larger flute is more effective for chip evacuation but it causes lower rigidity and as such makes the increase of the number of teeth more difficult.
This paper analyzes the motion of chips generated when using a spiral cutting edge and points out that there exists a different component of the angular velocity of chip from up-curl and sideward curl, which has not been discussed so far. Based on the analysis, a simulation model of chip flow is proposed and a high performance end mill was developed that has 45°helix angle and employs a flute geometry to guide the up-curl. The three-dimensional motion of chips is shown in side and groove cutting. The chips generated by the simulation are then compared with chips collected after actual machining.