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Significance Statement
This study investigates the contact interface for both a retired six-fluted end-mill cutter and a new one and then compares them using ultrasonic scanning, surface roughness measurement and SEM evaluation. One of the advantages of knowing the contact area is that it can be used for wear diagnosis because the increasing area size can be considered as a reference of tool life. In the cutting process, the tool needs to be replaced by a new one in order to maintain efficient cutting. In factory practice production, there is no standard solution to determine the correct timing for replacing the cutter. It is usually decided by experienced technicians based on visual inspection or the chip flow type. The finding of this study provides several comparisons including contact area, surface roughness and SEM views, in which the result can be considered as reference criteria for users to make the correct decision about changing a new cutter with the same type. In the future this method can certainly be applied to various cutters with complex contact and provide useful information.
Journal Reference
The International Journal of Advanced Manufacturing Technology, pp 1-10, 23 August 2015
C.W. Yao, L. Z. Zhou
Department of Mold and Die Engineering, National Kaohsiung University of Applied Sciences, 415, Chien-Kung Rd. Kaohsiung city 807, Taiwan, Republic of China
Abstract
This study investigates the contact interface for both a retired six-fluted end-mill cutter and a new one and then compares them using ultrasonic scanning, surface roughness measurement, and SEM evaluation. This is a static measurement, because the objective is to provide information for wear diagnosis. The relationship between the surface roughness and the contact area of the cutting teeth is also determined. The results show that the retired cutting teeth have an obviously smoother surface roughness and a greater contact area than those of the new cutter. The contact area between the six-fluted end-mill cutter and the specimen is calculated using an image analysis software package. The range of contact areas varies from 7.21 to 49.44 mm2 for the retired cutter and from 2.82 to 37.2 mm2 for the new item, depending on both the contact force and the definition of the contrast ratio. The SEM views of the surface topography of the end-mills under ×200, ×400, and ×800 magnifications are also presented.
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