Investigation of machining performances of the wave form end mills

In this study, the machining performance of wave form end mills with rake angle variable from -6 to +22 degrees and helix angle variable from 36 to 50 degrees on the helical cutting edge were evaluated. In this context, the machining performance of end mills with different wave geometries; within the framework of a four-stage work plan consisting of experimental, numerical, and statistical approaches on materials exhibiting different machinability properties; were evaluated in comparison with standard end mills, taking into account the criteria of cutting forces, surface quality and tool life. In the first stage, which consists of pilot studies, experimental works on C45 tempered steel, GG25 gray cast iron and AISI 304 stainless steel materials were validated with FEM (finite element method). In the second stage, FEM analysis was performed for all of the tools with different wave forms, high and low performance wave forms were determined. In the third stage, the effects of wave form tools on cutting forces and surface roughness on AISI 316L stainless steel and Ti 6Al 4V alloy which are difficult-to-cut materials were examined. In the last stage, the wear behavior of different wave form tools was investigated depending on the tool life experiments. As a result, the highest machining performance was obtained from the wave form tool defined as 8-250 with a wavelength of 8 mm and a wave amplitude of 250 µm compared to the standard tool. In the Ti 6Al 4V material, 26.5% lower cutting forces, 17.6% better surface quality and 73% lower tool wear were observed in the 8-250 tool compared to the standard tool. In the AISI 316L material, 17.2% lower tool wear was observed. Wave form end mills, which have become widespread in the field of machining and have not yet been mass-produced in our country, offer important manufacturing advantages for different manufacturing sectors and have created a high value-added product manufacture potential for companies producing cutting tools in our country.