Effects of edge preperation and PVD coatings on endmilling performance

In this study, the effects of the micro geometries and coating types have been evaluated on endmill working performance. In the tests planned in two stages, it was aimed to determine the most efficient corner rounding in the first stage and the most efficient coating in the second stage. In the first stage tests, in order to prevent vibration chatter free geometry (angle difference between teeth) were applied on the macro geometry, 3 different micro geometries as standard radius, waterfall radius and trompet radius were applied and AlCrN PVD coating were used. Kanal milling operations were carried out on AISI 4140, CK45 and hardened AISI 4140 materials in the tests performed on 3 different materials. After the first stage tests, abrasion and machine loads were checked as measurement criteria. Depending on the results of the first stage tests, two different coatings, AlCrN and TiSiN, were applied on the endmill with the least wear in the first stage tests. Coatings were tested on the CK45 and 4140 materials. These tests focused on the performance of the coating by optimizing the parameters. Then the tests were repeated on the GG25 material to evaluate the performance of the same coatings on a higher carbon material. An overall evaluation, it has been observed that micro geometries and coating have a direct effect on tool wear and performance. The best performance in micro geometries has been achieved in waterfall type edge preparation. When the coating types were evaluated, the best performance was obtained in AlCrN coating for all materials.