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Prediction of Cutting Forces of Solid End Mills With Differential Helix Angles: A Numerical Approach

[+] Author Affiliations
Hans-Henrik Westermann, Benjamin Thorenz, Robert Müller

Fraunhofer IPA, Bayreuth, Germany

Rolf Steinhilper

University of Bayreuth, Bayreuth, Germany

Paper No. DETC2016-59122, pp. V004T05A036; 8 pages
  • ASME 2016 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference
  • Volume 4: 21st Design for Manufacturing and the Life Cycle Conference; 10th International Conference on Micro- and Nanosystems
  • Charlotte, North Carolina, USA, August 21–24, 2016
  • Conference Sponsors: Design Engineering Division, Computers and Information in Engineering Division
  • ISBN: 978-0-7918-5014-5
  • Copyright © 2016 by ASME


Solid end mills with multi-section cutting edges and variable helix angles are available for application. New types of solid end mills for low energy consumption have recently been developed. These so-called Low Power Cutting (LPC)-Tools are characterized by differential helix angles.

Compared to solid end mills with variable helix angles, the new differential helix angles change their pitch continuously over the cutting edge length. Due to this fact the cutting conditions are not in a constant state during the revolution of the cutting tool. Existing mathematical approaches for the calculation of cutting forces only consider constant helix angles in milling operations.

This paper describes an approach for the prediction of cutting forces for differential helix angles. The developed mathematical model is based on geometrical considerations. Due to a continuously changing pitch over the cutting edge length a numerical approach for the mathematical model is chosen.

Copyright © 2016 by ASME
Topics: Cutting



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