Design of end mills equipped with disposable carbide and high speed steel inserts for machining of parts made of hard-to-process materials

The purpose of the work is to increase the machining efficiency of parts made of hard-to-process materials such as titanium-based alloys and high-strength stainless steels of the Cr-Ni-Si type by using special designs of end mills equipped with disposable carbide or high speed steel inserts. The work applies a theoretically justified and experimentally proved method of improving performance of special end mill designs by controlling the shape of the cut cross-section, which reduces the loads on the technological system and thereby intensifies processing modes. The simplest way to control the shape of cut cross-section is to use alternating cutting patterns. The proposed arrangement pattern of disposable carbide or high speed steel inserts located on one auxiliary technological helix allows to formalize the designing of special end mills and intensify milling modes at the stage of their design. This makes it possible to develop a designing methodology for special designs of end mills with disposable carbide inserts for milling hard-to-process materials. The use of calculation methods eliminates the influence of subjective factors of engineering stuff on the quality of tool design and reduces the complexity of design works. Creation of special end mills with disposable carbide or high speed steel inserts for rough milling of parts made of hard-to-process materials has intensified metal removal from 2 to 5 times, ensured a significant reduction in the consumption of tool materials in comparison with monolithic tool structures, and provided a multi-fold use of tool bodies as well.

end mills, disposable inserts, carbide alloys, high speed steels, hard-to-process materials, tool materials