International Journal of Research in Engineering, Science and Management 76

Volume 5, Issue 4, April 2022

https://www.ijresm.com | ISSN (Online): 2581-5792

Design and Development of Milling Cutter Tool

Aashu Gupta1*, Ananaya Singh2, Ashok Kumar Madan3
1,2
Student, Department of Mechanical Engineering, Delhi Technological University, Delhi, India
3
Professor, Department of Mechanical Engineering, Delhi Technological University, Delhi, India

Abstract: When we analyze an end cutting tool statically, we insert in the research, is a good example of a high-speed steel
must take into account a variety of factors such as heat to machine mold. The following are some of its characteristics:
distribution, cutting force and torque applied to the tool, wear, and
1. At room temperature, it has a tensile strength of 1044
vibration. The goal is to design and analyze a milling cutting tool.
SolidWorks-21 was used to design the cutting tool, which in this Mpa.
case was an end mill tool, as well as to do the static analysis. The 2. Hardness ranges between 280 and 320 HB.
external loadings are as follows: The end mill cutting surface is With increasing cutting speed, feed rate, axial depth, and
subjected to torque of 26 N/m. One of the tool surfaces is subjected radial depth of cut, tool life diminishes. The chemical
to 1250 N of force. After running the simulation in SolidWorks – composition of the carbide coated tool has an impact on its wear
21, the lowest FOS and maximum resulting displacement were 12
rate. When constructing a milling cutting tool, there are three
and 0.0969mm, respectively. It is evident from the preceding result
that the tool is less likely to break. key elements to consider during the machining process, the
temperature distribution was monitored, Torque generated ,the
Keywords: Cutting force, vibration, end mill tool, static analysis, amount of cutting force applied to the tool and Cutting force
loadings. exerted on the tool.
This is critical in order to avoid tool failure. The temperature
1. Introduction in the cutting zone at the tool-chip interface can reach 1000
In the milling process, the chip bearing process occurs due to degree C during machining. The torque recorded when
lateral plastic flow of material that forms burr at the edge of the workpiece material stainless steel AISI 618 is end-milled with
shear zone. The performance of a cutting tool affected by three carbide inserts PVD coated with a layer of TiN is listed in Table
factors that play the important role: 1. Because 23Nm is the maximum result from Table 1, we
1. Hardness conclude that the tools must be able to tolerate a torque of 23Nm
2. Wear resistance in order to avoid tool failure.
3. Chemical inertness Table 2 displays the cutting force, and we can see that the
4. Fracture toughness of the workpiece material. tools must be able to bear forces more than 1250N in order to
Because of the combination of high temperature, high avoid tool failure. This is proven by Kadirgama's experiment
workpiece strength, work hardening, and abrasive chips, with Hastelloy C-22HS as a workpiece material. According to
notching at the tool nose and depth of cutting region was a Fuh and Hwang's experiment, when a 20mm helix angle is
common failure mode when machining nickel-based alloys. utilized and a 30o helix angle is employed, the maximum
Special physical circumstances, such as stress and high milling force is 722.7N. The forces acting on the tool in the
temperatures, are the most typical causes of tool wear. orthogonal cutting method, according to Dombovari and
It is critical to keep track of tool life in order to avoid losing Stepan, can be illustrated as shown in Figure 2, where the shear
time on tool replacement and resetting the tool during force, Fs, and normal force, Fn are as follows:
machining.
Carbide tips type cutting tool usually suffers flank wear as
shown in figure below.

Fig. 2. Forces acting on a tool in 2D cutting

Fig. 1.

The AISI P20, which was milled utilizing a carbide coated

*Corresponding author: aashuiitian@gmail.com

A. Gupta et al. International Journal of Research in Engineering, Science and Management, VOL. 5, NO. 4, APRIL 2022 77

Table 1 half of all tool damage cases, and they are caused by thermal
Experimental torque measured
fissures in the straight cutting edge.
Properties of high precision parts are improved by cold
treating them to temperatures ranging from -125 to -196 degrees
Celsius to increase hardness and improve hardness
homogeneity. The cryogenic treatment is what it's called.
Unlike coating, this ensures that the tools will retain their
quality following regrinding or resharpening. H13 tool steel
samples that were deep cryogenically treated increased the wear
characteristics of the steel by producing homogenous and very
tiny carbide particles.

2. Methodology
Using Marrow correction and fatigue analysis on the cutting
tool, an integrated Finite Element (FE) based analysis assists us
in producing optimal tool material. Under the set cutting
parameter, it can forecast deformation, stresses, and strain in the
workpiece, as well as the load on the tool. Techniques based on
the Finite Element Method (FEM) can provide more detailed
information on not just cutting forces but also tool stresses and
Table 2
temperatures. When employing a fresh cutter, the static cutting
Experimental cutting force (Kadirgama) force increases as the axial depth of cut increases. The attempt
made in this project design and development is to employ
cryogenic treated H13 tool steel as the material for the end mill
because it may give a uniform material hardness distribution
when compared to coated tools, which is ideal for resharpening
and regrinding. SolidWorks-19 is used to model the end cutting
tool in as much detail as feasible. Figure 3 shows the planned
H13 tool steel end mill.

Knowing the resultant forces is not enough to model a tool

during design; knowledge of the forces involved is required to
design a tool that can withstand the relevant forces.
Solid and coated carbide also have a higher hardness than
high-speed tool steels, allowing for faster cutting speeds and
material removal rates (HSS). The rake angle of the tool has an
impact on the friction and contact zone between the chip and
the tool. We discovered that as the radial rake angle increased,
the side burr thickness decreased linearly. When the radial rake Fig. 3. 3D modeling of a 25mm diameter and 180mm long end mill
generated by using Photo View 360 in SolidWorks-19
angle was between -30 and 30 degrees, however, it was
practically constant.Wear processes between the workpiece and
the cutting edge are important because they influence tool 3. Static Analysis
material selection for high-speed cutting. Static analysis was done on the intended end mill to estimate
To increase tool life, coating carbide tools was first created the likelihood of the tool breaking or failing under static
using the Chemical Vapor Deposition (CVD) technology, and loading. SolidWorks 2021 Simulation was used to do the finite
most multi-layer coating materials contained a combination of element analysis. According to the literature reviewed, which
TiC, TiN, Ti(N,C), and Al2O3 with varied deposition included books and research articles included in the references,
sequences.TiC coatings provide for great flank wear resistance, the maximum force and torque exerted on the tool throughout
whereas TiN coatings allow for negligible crater wear. A12O3 the cutting operation were considered. External loads were
or ALON, on the other hand, remain chemically stable even at applied to one of the tool surfaces, resulting in torque of 26 N/m
high temperatures because to their low avidity, and repeated and forces of 1250 N.
coatings with ALON exhibit reduced crater wear. The following are the physical parameters of the H13 tool
Tools with an oxide coating perform better when used for dry steel that was used:
cutting operations. Fracture and chipping are seen in around 1. Density-7800 kg/m3
A. Gupta et al. International Journal of Research in Engineering, Science and Management, VOL. 5, NO. 4, APRIL 2022 78

2. Tensile strength-1990 Mpa wear out quickly, limiting their useful life. This is why
3. Yield strength temperature distribution is critical in determining a material's
4. Shear modulus: 81.0 Gpa compatibility for a tool and limiting the tool's application.
5. Poisson's ratio: 0.3
Figure 4 depicts the location on the end mill tool where force
and torque were applied to conduct the simulation. The green
arrows denote the fixture region where the tool was held in a
fixed position to simulate the tool holder holding effect for a
more realistic result.

(a)

Fig. 5. Solidworks-19 simulation result (a) FOS and (b) resultant

displacement
(b)
Fig. 4. FEM external load setup (a) Force and (b) torque 5. Conclusion
In this research, we aimed to create a milling-specific cutting
4. Result and Discussion tool. After reviewing the literature, we opted to use cryogenic
The result of the simulation using SolidWorks 2021 treated H13 tool steel for the end mill since it can produce a
Simulation is presented in Figure 5 below, which includes the more uniform material hardness distribution than coated tool
FOS and the resulting displacement in millimeters (mm). steel. We achieved a decent FOS of 12 and a displacement of
The key section of the design, as shown in Figure 5 (a), is 0.0969 mm as a result.
near the end of the tool holder, which has the lowest FOS. It We attempted unsuccessfully to use a more specialized
also demonstrates that the particular region is where stress software, Thirdwave AdvantEdge, which would have provided
concentration occurs, implying that special care should be made a superior result in terms of thermal stress, toll performance,
in tool design and material selection. The FOS color tone also and vibration. In conclusion, our study's goal was
illustrates that the stresses are higher in the area where the tool accomplished.
design geometry changes. Figure 5 (b) indicates, on the other
hand, that the highest resultant displacement occurs at the References
cutting tool edges' tips. [1] K. Kadirgama, K. A. Abou-El-Hossein, B. Mohammad, H. Al-Ani, and
As indicated in Figure 5, the minimum FOS is 12 and the M. M. Noor, "Cutting force prediction model by FEA and RSM when
machining Hastelloy C-22HS with 90 holders," Journal of Scientific &
highest resulting displacement is 0.0969mm, based on the Industrial Research, vol. 67, pp. 421-427, 2008.
simulation using SolidWorks 2021. The tool is less likely to [2] K.H. Fuh and R.-M. Hwang, "A predicted milling force model for high-
break as a result of the results gathered. speed end milling operation," International Journal of Machine Tools and
Manufacture, vol. 37, no. 7, pp. 969-979, 1997.
In actuality, even a single vibration can cause premature tool [3] Z. Dombovari and G. Stepan, "On the bistable zone of milling processes,"
failure when it is subjected to dynamic loads, vibration, and Philosophical Transactions of the Royal Society of London A:
heat stress. Even high temperatures in tools can cause them to Mathematical, Physical and Engineering Sciences, vol. 373, 2015.