Development of an Energy-Efficient Cutting Edge Geometry for Solid End Mills: A Design of Experiments-Based Approach

Abstract

Milling operations are commonly characterized by high energy consumptions and should be in focus for optimizations aiming sustainable manufacturing processes. Research results show that within milling operations, especially in small and medium enterprises (SME), up to 80% of the applied milling cutters are solid end mills. The paper presents a design of experiments (DOE)-based optimization of the cutting edge geometry, to improve the energy efficiency and technical capability of solid end mills. Thereby the paper describes the fractional factorial design for the first-degree polynomial model as well as the subsequent set up of a central composite design (CCD) with its second-degree polynomial model for the optimization of relevant target parameter like cutting performance, tool wear and surface quality. Based on the results of more than one hundred machining tests this comprehensive approach shall contribute to the development of new cutting edge geometries of solid end mills and thereby lead to more energy-efficient machining operations in milling applications.