SolidTool - Performance increase of solid carbide end mills through process chain optimization

 

Coated solid carbide end mills are used, among other applications, in mechanical engineering and the automotive industry. Despite the extensive and intensive use of these milling tools, the level of knowledge about the effects of the production-related surface and edge zone properties of solid carbide end mills on their performance was low at the beginning of the project. In addition, the interrelationships and interactions of the respective manufacturing processes along the process chain for manufacturing these tools were insufficiently known. Since the production-related tool properties of the milling cutters were not optimally matched with regard to their application behavior, the performance potential of the cutting material had not yet been exhausted.

The aim of the project was to create a knowledge base for the production of high-performance milling cutters whose application behaviour exceeds that of conventionally produced milling cutters by methodical research into the influence of the production-related surface and edge zone properties of coated solid carbide milling cutters on their functional behaviour and their development along the process chain. In order to achieve the project objective, different surface and edge zone properties of the tools were generated by varying the manufacturing processes in the process sequence and the development of the production-related tool characteristics along the process chains were analysed. The tool characteristics were then investigated with regard to their influence on the milling cutter’s application behaviour. Based on the results of the tool life investigations and the findings from the analysis of the production history, design approaches for an optimized production process sequence for the manufacture of solid carbide end mills were then derived.

The aim of the research project was achieved.