Development of a High Performance End Mill Based on the Analysis of Chip Flow Generated by Curved Rake Face

To achieve high efficiency machining with end mills, the analysis of chip flow is necessary. Firstly, the constraints which a curved rake face gives to chip flow are analyzed, and the existence of the third component of angular velocity of the chip, which is different from those of up-curl and sideward curl, is found. Secondly, based on the analysis, a simulation model of chip flow is proposed, thus leading to the development of a high performance end mill. Finally, the chip configurations and chip flow obtained by the simulation are compared with those observed in actual cutting tests for verification.