Inverse cutting technology - a new strategy in face milling

• Applicant: Professor Dr.-Ing. Bernhard Karpuschewski, since 12/2020
• Subject Area: Metal-Cutting and Abrasive Manufacturing Engineering
• Term: from 2016 to 2022
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 316141494

The proposal based on the running project GZ: (sign removed) aims to improve process stability at increasing productivity in face milling. This is realised by reducing the cutting ratio b/h (undeformed chip width b to undeformed chip thickness h). If the strategy of low cutting ratio is realised up to b/h < 1, many cutting parameters and mechanisms are inverted. It can be referred to as “inverse” cutting technology. Adapting cutting parameter (decreasing the depth of cut ap and increasing the feed per tooth fz) to the lowest cutting ratio, the cutting process is stabilized. With decreasing cutting ratio the direction of the declination force vector turns towards the spindle axis. Accordingly, a low cutting ratio has a positive effect on process dynamics.The project objective contains topics from basic investigations on the effect of the inverse cutting ratios on cutting force, process dynamics and process temperature in milling, which are leading to practical process and tool design. The main milestones are the development of models for calculation of process forces, tool deflection und residual stresses, investigations on stepped cutting and helical positioning of the cutting edges, extension of the Kienzle force model, design of micro and macro tool geometry, investigation on cutting speed influence on surface integrity at inverse cutting. Finally, the combination of inverse chip formation and high-speed cutting is intended to significantly optimize the face milling process in terms of surface integrity and productivity.

• DFG Programme: Research Grants
• Co-Investigator: Dr.-Ing. Thomas Emmer
• Ehemaliger Antragsteller: Dr.-Ing. Florian Welzel, until 11/2020