Mechanics, dynamics and optimization of special end mills

Official URL: http://risc01.sabanciuniv.edu/record=b1534373 (Table of Contents)

Machining, especially milling, is still one of the most commonly employed manufacturing operations in industry because of its flexibility and potential to produce high quality parts. Milling performance can be increased significantly using special milling tools, such as variable pitch and helix or serrated end mills. The literature on these special tools is mostly limited to prediction of milling forces and chatter stability. Although there are very few studies on optimal design of variable pitch and helix tools, no work has been reported on selection or optimization of serrated end mills. In this thesis, mechanics and dynamics of these tools are investigated in detail. Furthermore, methods and their results on optimization of these tools for minimized milling forces and increased stability are also presented. Optimal variable pitch tools are designed for a given milling system and a desired spindle speed, using different pitch patterns. Their performances are compared and some important and practical results are found. The effects of serration waveform geometry on cutting forces and chatter stability are also investigated in detail. According to the optimization results, guidelines for selection and design of these tools are proposed.