Prediction Model of End Mill Cutting Edge Based on Material Properties and Cutting Conditions

In machining, the cutting performance of the tool depends on the tool material, tool structure, tool geometry, properties of workpiece materials, and cutting conditions. If the user chooses an inappropriate cutting tool for the machining of the workpiece material, this will cause energy loss and severe tool wear. This study aims to investigate the influence of mechanical properties of workpiece material and cutting conditions on the tool geometry and to establish a polynomial network for the prediction of a reasonable normal relief angle and a normal wedge angle based on experimental data. Experimental results indicate that the cutting of high hardness and high strength workpiece materials requires a larger normal wedge angle to increase the cutting edge strength. In addition, the design of the normal relief angle is related to Young\u27s modulus and the toughness of the workpiece material, mainly to avoid material elastic recovery during the cutting process. In terms of cutting parameters, as the radial depth of cut increases, the contact area between the tool and the chip increases, which causes the heat to concentrate at the tip of the tool; hence, it is necessary to increase the normal wedge angle. In addition, the feed per tooth had a negligible effect on the normal wedge angle. Finally, the prediction model was verified by five untested workpiece materials. The results of the cutting tests showed that the flatness of the cutting edge was less than 15 μm, which indicates that a normal cutting phenomenon occurred on the flank