Design of end mill cutter with applying FEM-method

In order to fulfil the increasing requirements of the industry better, the regular application of the finite element method (FEM) seems to be unavoidable. The recognition of this fact can be noticed in case of non-series tools still less, but manufacturing companies (wishing to remain competitive in the future as well) use softwares, based on the finite element method and simulating the cutting processes, also nowadays. The aim to develop these softwares is to design and produce tools, maximal fulfilling the demands of the customers and at the same time, enabling the reduction of design and production costs of the tool manufacturers. As a result of the use of the softwares we can be able to predict the occasional tool deformations, avoiding the break of the tool, the unfavourable chip deflection, the undesirable deformations of the workpiece, etc.

Evaluation of cutting performance on Pramet carbide inserts with several coatings, made by Platit AG

One of the most prosperous fields of the tool innovation – beside the development of tool construction and the expansion of the circle of the usable tool materials – is the field of evolution of materials and methods of the coatings where an explosion-like development can be noticed. The development of various capacity of coating units makes it possible for us to choose from coating types, we never had before. Beside the universal applicable coatings types there are special coating systems (PM HSS hob, drilling of Ni-base alloys etc.) as well, developed for a given task, increasing the cutting performance of the tools significantly.

New methods in qualification of cutting performance during drilling operation

The improvement in cutting performance of the innovative tools cannot be linked solely to one criterion. The judgement of the cutting performance, made based on some simple factors (chip formation, comparison of surface roughness, edge durability etc.), is quite subjective. During the qualification, based on instrumental measurements, effect of those factors will be considered as well which can serve as the base of the tool monitoring with on-line registration of the wear process. In our present article we are going to introduce a qualification method, worked out for innovative drilling tools and applied successfully: it is able to characterize the effectiveness of the innovation based on some features of the cutting performance (force effect, torque demand), measured at the same time. The elaborated method makes it possible to promote data generation in order to create calculation formulas with the limiting conditions during the planning phase of the machining technology and to improve the process security.