Experimental and statistical investigation of the machining performance of wave form end mills on AISI 316L stainless steel

Abstract

Wave form end mills with variable rake and helix angles are new in the machining industry, and limited information is available on their machining performance. In this study, the machining performance of wave form end mills with variable rake and helix angles on the helical cutting edge on AISI 316L austenitic stainless steel which is in the difficult-to-cut materials due to work hardening, high tool wear and build-up edge (BUE) was investigated. In this context, five different carbide cutting tools, which are wave form tools with different wavelengths (mm) and wave amplitudes (mu m) (6-550, 8-250, 4-450, and 8-650) and the standard tool, were evaluated through both experimental and statistical approaches in consideration of cutting forces, surface quality, tool life criteria. In terms of cutting forces and surface quality; wave form tools exhibited higher cutting forces and surface roughness values than the standard tool in all machining conditions, due to the predominance of machining negativity in negative rake angle regions despite the advantages provided by the positive rake angle regions. On the other hand, in 8-250 and 8-650 waveform tools with smaller positive and negative rake angles (+4 degrees, -2 degrees, -3 degrees) were observed low tool wear values 17.2% and 6.9%, respectively compared to the standard tool. As a result, it is thought that 8-250 and 8-650 wave form tools can be a solution in rough milling processes for the low tool life problem caused by high mechanical strength and high work hardening properties that make difficult-to-cut AISI 316L material.