Cemented Carbide End-Mill Edge Preparation Using Dry-Electropolishing

Abstract

Precision edge preparation techniques for cemented carbides enable optimization of the geometry of tools’ cutting edges. These techniques are frequently used in high-stress environments, resulting in substantial improvements in tools’ cutting performance. This investigation examined the impact and evolution of cutting edge parameters and resulting surface finishes as a function of dry-electropolishing time on an end-mill. Findings demonstrate enlargement of the cutting edge radius, a decrease in surface roughness, and the mitigation of defects induced during previous manufacturing stages (i.e., smashed ceramic particles, burrs, chipping, etc.). Additionally, a direct correlation between dry-electropolishing time and primary cutting edges’ micro-geometry parameters has been established.

Digital twin of the technological process for grinding helical flutes of a cutting tool

“…In this connection, to ensure production flexibility, it is necessary to use such flexible methods of technological preparation as the possibilities for producing various standard sizes of end mill designs are wide. End mills have found wide application in mechanical engineering, aerospace, and the production of agricultural machinery [21,22]. The designs of end mills have a wide variety: when milling parts with thin walls with low rigidity, uneven force deformation occurs, obvious problems with vibrations; cutters are used to reduce vibrations with variable cutting edge pitch [23]; Ceramic end mills are used for processing heat-resistant materials [24]; In addition, there are many standard traditional end designs with helical flutes with profiles of various shapes as shown in [25]; high-performance processing of steels and cast irons is carried out using end mills with a double toroidal cutting surface [26,27]; For finishing machining with greater stability, multi-flute cutters with a shallow profile and a long transverse cutting tooth are used [28].…”